[heatmizer]

Need to cut iec jack into 4 mm aluminum panel. Am looking for a good method of cutting. Will probably use a dremel or a sabre saw. Anyone have any advice?

 

[Pars]

Nibblers? I used these on fairly thick aluminum, and they worked well (but it was a bit of work).

 

[balrog]

you could chain drill it then clean it with a file.

If you have a steady hand, taking light passes with a cutting wheel mounted in a dremel . Tape off the area to avoid a scratch if you slip. Maybe cut from the inside of the panel .

 

[DolbyR]

I dit mine using a powerdrill, a dremel with cutting wheel and a file. Didnt come out "factory-clean" but from the outside you can't see a difference

My panel in only 2mm aluminium though.

 

[fordgtlover]

I'd be tempted to drill around the hole and then clean it up with either a dremel or a file.

 

[heatmizer]

Think I will try holes around then cut between with dremel.

 

[MisterX]

Good luck with that.
I got real sick of drilling the holes so I just drilled one in each corner and jumped right to the dremel part on the 4mm panel I just did.

 

[stevenkelby]

I would drill holes in the corners then perform an ancient technique utilizing an outmoded form of energy commonly known as a "hand tool". A coping saw to be precise. The blade comes undone so you can pass it through the hole, re-mount it then make your cut by moving your hand in a back and forth fashion. Tricky the first time but gets easier.

They look like this, if you can still find one in this day and age:

 

[heatmizer]

Seems to be some kind of cordless saw. Where do you put the batteries

 

[MASantos]

Quote:

Originally Posted by heatmizer /img/forum/go_quote.gif Seems to be some kind of cordless saw. Where do you put the batteries

are you serious? It doens't use batteries. you actually have to use your hands and do some effort!

 

[rustbucket]

I think old-school tools don't get nearly enough credit. I used a drill/dremel for years for various metal cutting tasks, and have recently been using a hacksaw, coping saw and file. I get much better results from hand tools.

As an added bonus, I don't need to wear earplugs, safety goggles or a dust mask.

 

[el_matt0]

i think it was a joke (obviously) :| lol. but yea ive done a couple of IEC holes on 4+ mm panels, even thicker than that too. and i found the best way to do it is to drill out the corners with a decently large bore bit, then use a dremel or hand saw of some sort to cut from hole to hole. when i did it, after removing the center piece, i still had a LOT of excess material left. what i found best for filing was a heavy duty course file, flat and about 1.25 inches wide (about the same width as any side of the "square" hole). that allowed me to simply use the flattened 1 inch wide blade of the file to produce nice even, flat, filed edges. its not the speediest process obviously, so it allows u quite abit of time along the way to correct any awry looking edges and whatnot, so that you dont end up with a weird looking quadrelateral instead of a square!

 

[DolbyR]

el_matto, that's exactly the technique even I used, and i believe is the best one. Though my drilling sucked so the shape became kinda strange as one of the holes was bit off. But i'm fairly satisfied with the result.

 

[Uncle Erik]

Quote:

Originally Posted by rustbucket /img/forum/go_quote.gif I think old-school tools don't get nearly enough credit. I used a drill/dremel for years for various metal cutting tasks, and have recently been using a hacksaw, coping saw and file. I get much better results from hand tools. As an added bonus, I don't need to wear earplugs, safety goggles or a dust mask.

I go with the handtools, as well. However, for inside cuts, I'll still power drill a hole to start from.

You get a lot more control over the handtools and without having to do extensive setup, you can actually get work done faster.

Not to threadjack, but the same goes with woodwork. It pays to use powertools for ripping big pieces, but after that, go entirely with hand tools. The work takes about the same amount of time, but the quality is higher, you make fewer mistakes that ruin a piece, and the risk of injury goes almost to zero.

 

[heatmizer]

Um, I made a joke. I know what a coping saw is.

Hardware store does not any coping saw blades with very fine teeth though. Best they had was 12 teeth per inch. Think I want at least 18 for metal work.