cutting metal rack panels

[novasak]

I'm making some rack panels (using the Penn blanks) to hold Speakons and some other switches and jacks, but I've got some square switches I want to use.

What tool can I use to cut square holes in these metal panels? and Should I be using any certain type of bit to drill out the 1" speakon holes? I've only done the 1/8" and 1/4" ones so far with decent results. But the larger holes and definitely the square ones I don't know how to go about.

I can't afford to purchase a drill press, though it would be nice.

any ideas?

[Bill Fitzmaurice]

Greenlee punches for the square holes, Varibit for the 1".

[Vuja de]

Greenlee punches for the square holes, Varibit for the 1".

These might be a cheaper alternative granted they don't have the square punches you ask for.
Greenlee punches are not cheap.

http://www.parts-express.com/pe/showdet ... er=262-295

[horst]

these are those plastic rocker switches?
they may look good and have a nice low profile, but they're only held in by plastic springs and you have to get the hole exactly right else or either you really have to force them and possibly strip the springs, or they will be lose, forever.
I'd say ditch them and get switches with require a round hole, and are held on with a nut.

[Ron K]

Try here for square hole punches. I doubt you find any that are really cheap and still any good.

http://www1.mscdirect.com/CGI/NNPDFF?PM ... &PMCTLG=00

http://search.eastwood.com/search?w=hol ... 5QoddRjTJw


If you have access to a milling machine use a small 1/16" End Mill and you can cut 1 hole in roughly 2 mins time if your setup is decent!

On another note if you would get access to a Mill simply get a chunk of S7 Steel and make your own die punch. Then use an Oxy/Acetylene torch to harden it the rest of the way.It wont need to be through hardened just a deep oil quench surface harden should do for that ga. of steel you need to punch.If you get the die edges just right you should be able to punch the holes using a standard vise and little effort.

[bitSmasher]

Drill + small file. A dremel would be easier than a file... but Horst has a point, are they designed to just clip in? Not a good long-term solution.

[Harley]

I'm making some rack panels (using the Penn blanks) to hold Speakons and some other switches and jacks, but I've got some square switches I want to use.

What tool can I use to cut square holes in these metal panels?
?

I use this.

Drill 1 1/4" hole to poke the punch through and away you go. It's a bit of an art to get used to so practice on some tin first.







I bought this at Dick Smith Electronics ( USA read Radio Shack )

[novasak]

yikes, $400 for a punch!? I'm only needing to use this twice, so maybe I should just get some round switches.

My other idea is to just get them professionally done. Anyone use http://www.frontpanelexpress.com ? From a rough design I did, with 14 round holes and two square ones, the price is about $70. That is for a natural aluminum panel and no printing, but it's still cheaper than buying tools I'll only use a few times.

[Ron K]

http://www.markertek.com/custom.asp#RSH

They do all types of custom Audio Video Panels. Best to call them and talk with a rep and see if they can help you out.

PM me if you want a better price on a machined panel.I'm sure I can do better then $70.00.

You put your own round holes and send me the blank and I'll cut the square ones for you and send it back if you want to save more $$$$.

It would be reasonable and you could pay with Pay-Pal.

[gdougherty]

Todd, you can also call people you know locally who might have a drill press in their shop, a full set of cobalt metal bits and a $50 Neutrik D series sized bit from upgrading 1/4" returns to XLR returns on his snake. Just a thought.

[Harley]

yikes, $400 for a punch!?

So, what is wrong with the $25 hand punches I posted above?

You have to nibble away one cut at a time. A 1" square would take you about 5 minutes. With a little practice they work a treat.

[horst]

yikes, $400 for a punch!?

So, what is wrong with the $25 hand punches I posted above?

they weren't in focus

[Harley]

they weren't in focus

Huh?...it's you Aussies calling us "the shaky isles" because NZ just happens to lay on a geographical fault line.

Now you know why some of my pics are a bit fuzzy.

[bitSmasher]

I'd blame it on the Steinlager.

No need for custom work or going over the top with making punches.
Simple enough to rely on a nibbler + file, or Dremel + file. You'll still need to drill a pilot to start, not a big deal though.
Either way, the tools aren't overly expensive and you'll always find a use for them - a dremel/similar is a great investment for small fiddly stuff.

[novasak]

Harley, I'm definitely looking at getting a nibbler. I was just commenting on the Green Lee

George, I totally forgot you have a bunch of tools, I'll give you a ring when I have my holes plotted out and we'll hang out again.

Thanks guys.