- Thread starter SpeedyJD
- Start date
Spark plug
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If you ha lots to do a q-max type punch would be my choice but for just the odd one then just use what you have to hand, chain drill and file will probably be my choice for Dutch a small hole.
brightspark
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4 holes in corners jigsaw and file job done
I think if I had a lot to do, I would make a die and punch, harden it and then use a decent fly press or hydraulic press
Paul.
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4 holes in ally is a half hour job at most, last week I made 5 location plates from 2mm stainless 85mm x 25mm with a 30 x 16 rectangular hole and 2 csk fixing holes, all hand made with a drill and hand files in 45mins from start to finish including polishing, its basic metalworking.
123hotchef
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plasma cutter
brightspark
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how many u making ??if it were a fair few and your not so handy with the file make a steel template up lay over and file it 
123hotchef
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jigsaw for me too I think
Screwdriver
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Almost sounds like there's not enough room there. 40mm box, knock out 30mm and leave two 1/8" edges?? Gonna be tight.
8ob
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I think it may be worth getting one of these and make or have made the 30mm square tooling.
http://www.ebay.co.uk/itm/10-Ton-Hy...829590?hash=item33ba4b4e96:g:WVsAAOSwhOVXclhJ
Bob
http://www.ebay.co.uk/itm/10-Ton-Hy...829590?hash=item33ba4b4e96:g:WVsAAOSwhOVXclhJ
Bob
I'd drill a big hole and then file out the edges... 30mm hole isn't that big
going into 40mm box is the real limiting factor, hard to get in behind the hole, and not much space either side of it
if it's going to be a regular thing... make a jig and plasma it ?
going into 40mm box is the real limiting factor, hard to get in behind the hole, and not much space either side of it
if it's going to be a regular thing... make a jig and plasma it ?
morssdn
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30mm holesaw then a shortened blade jigsaw so it doesn't hit the far side if that's an issue. I find you can control jigsaw quite well when cutting out steel square holes, this would keep the filing down. A die grinder with a suitable cutter might make quicker work of the filing/tidying.
The Starrett thin wall holesaws seem to work quicker than the traditional holesaw and are easier to get the cutout out of. Eg http://uk.rs-online.com/web/p/hole-saws/0466794/
The Starrett thin wall holesaws seem to work quicker than the traditional holesaw and are easier to get the cutout out of. Eg http://uk.rs-online.com/web/p/hole-saws/0466794/
Screwdriver
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If I had to do more than say half a dozen, I'd make up a punch as stated above. Couple of chunks of hardenable steel and a big bolt. Having the die constrained within a box section would probably make it a lot easier in use.
I've never used a die and punch before. Is it a case of making (or buying) a hardened steel box section that will slide inside the aluminium box section which I want to punch. Then a 30mm square punch that will punch out the square? Will it not flatten or distort the aluminium box section? What cuts it? Sorry for sounding a bit dim.
Screwdriver
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Imagine a square with spikes pointing down from each corner. There's a hole in the middle and it fits into a square aperture with sharp edges. The aperture is built into a box deep enough to accept the punch with a hole at the bottom or a built in stud so you can pull the two together.
Bit like this:
https://uk.rs-online.com/mobile/p/punch-die-combinations/0541286/
Bit like this:
https://uk.rs-online.com/mobile/p/punch-die-combinations/0541286/
