Cutting holes in diecast boxes

[Perry Owens]

I need to cut some rectangular holes in some diecast boxes to fit sockets etc. Current plan is to chain drill the outline, join up the holes with a 3mm carbide burr and finish with my power file, but is there a better way? I have an abrafile but it's too long to use on the small boxes.

 

[Seadog]

That's how I've done it. What is the hole size? Maybe a step drill woul speed up the process.

 

[Perry Owens]

That's how I've done it. What is the hole size? Maybe a step drill woul speed up the process.

Good idea - I have some step drills somewhere about.

 

[Screwdriver]

Can they be punched out on a Flypress? I know those castings can be quite brittle but if everything is flat and properly supported, worth a try if you have loads to do.

 

[MoreWellie]

It depends on the size/shape but you can buy rectangular and square Q Max cutters

 

[Perry Owens]

I only have half a dozen to do but all different sizes, so it won't be worth getting dies or Q-max punches. I'll just have to get the trusty Fobco to work then cover myself in fairy glitter with the burrs.

 

[mike 109444]

You should be able to come in at an angle with an abra file and they cut sideways as well

 

[brightspark]

jig saw with metal cutting blade. drill the corners to fit the blade in to start cut

 

[voipio]

Pilot hole then fretsaw.

 

[Dieselman 63]

I had to enlarge a hole on my power box. I used a dremel with a grinder stone. If I was going to add a new one I would support the underneath with a block of wood and drill, then grind out to diameter. You can see why plastic is more practical, but you can’t beat the look of vintage switch boxes!

 

[awemawson]

I guess that's the advantage of having a CNC milling machine - these ones were for battery maintainers for the servo axis drives on my (now sold) Traub TNC350G 5 axis CNC lathe that I rebuilt

 

[Allthegearnoidea]

Do those router drills work?