Cutting holes in metal case

[ebaudio]

I'm looking for suggestions on the best way to cut rectangular or square holes in a metal case.

I racking up some pres and have greenlee punches for the XLR and 1/4" holes so that is no problem. I need to make a couple of rectangular holes though and want it to look good. A hacksaw and file seems obvious but I am questioning my ability to cut a straight line....

Anyone tried a nibbler or have other ideas?

[leftofthedial]

A vice, a small (4 1/2") circular saw with a metal blade (ie. no teeth), "Goggles".
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[The Scum]

What materials?

Aluminum is pretty easy to work. Steel isn't.

I've used all manner of things through the years.

A little nibbler will do for aluminum.

A Dremel with a variety of blades is also useful. Spend the extra money on the high grade abrasive discs. Face shield should be considered mandatory.

An arbor press with punches can be useful...but a big enough press to be useful in all situations is large, heavy and likely expensive. Thankfully, the technology hasn't changed in ages - a WWII era one can get the job done, and they show up used frequently.

A milling machine will cut all sorts of slots and square holes, without the limitations of the shape of a punch.

A CNC plasma cutter is probably the ideal tool for odd shaped holes in a wide variety of materials.
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[ebaudio]

The front panel is 0.125 aluminum. Rear panel is 0.05 steel. I'm looking at the Par Metal cases.

Front panel is a large cutout for the module and rear panel is an AC Inlet cutout....

[Scodiddly]

Par metal cases are maybe a bit too heavy-duty for a nibbler, though the cheap one from Jameco is a pretty good tool and might do the job. Otherwise the Dremel tool with the abrasive discs.

[Scodiddly]

Par metal cases are maybe a bit too heavy-duty for a nibbler, though the cheap one from Jameco is a pretty good tool and might do the job. Otherwise the Dremel tool with the abrasive discs.

[ebaudio]

Thanks everyone.

I have a few dremels and haven't had much success in getting the lines cut straight but I will take a look at some different discs. A small circular saw is cheap enough that I may get one and try it as well.

Always good to have a reason to buy a new tool....

[Thomas W. Bethel]

You might want to find a machinist with his own home shop or look for a machining job shop. They can be very accommodating and usually don't charge an arm and a limb for their services. FWIW
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-TOM-

Thomas W. Bethel
Managing Director
Acoustik Musik, Ltd.
Room With a View Productions
http://www.acoustikmusik.com/

Doing what you love is freedom.
Loving what you do is happiness.

[mrc]

What he said! +1

[The Scum]

if you're looking into outside jobbers, check out Front Panel Express.

They have a little CAD application that you download, then use to design your panel...holes, engraving, etc. You press the "send" button in the application, and they'll do the machining for you.

They'll even use your material...though I'm not sure they'll do steel. I've had them do big rectangular holes in ParMetal cases before, always with top notch results.
_________________
"What fer?"
"Cat fur, to make kitten britches."