[scytheavatar]

So far I am using drill holes -> file, and the filing part can get really annoying, especially when you need to be careful of not scratching your case. So does anyone have a better idea as to how you can make those rectangles for your IEC sockets and buttons easily and quickly?

 

[dbfreak]

With the tools available to you, that is really the only way.

 

[Uncle Erik]

There are square chassis punches available (sometimes called a conduit punch) but they don't usually come in the right size for an IEC jack.

Do you have a jigsaw? If so, you can use a fine toothed metal blade to carefully trim inside the outline of the hole you need to make. You'll still need to file it smooth and square, but it'll be a lot less work than filing round holes into square ones.

If you're worried about nicking or scratching your chassis, put masking tape or that blue painter's tape around the area you're working. The painter's tape is a little better because it'll usually come off without leaving residue behind.

 

[El_Doug]

Youd be really surprised how many things you can do with nothing more than a dremel

 

[pabbi1]

Quote:

Originally Posted by El_Doug /img/forum/go_quote.gif Youd be really surprised how many things you can do with nothing more than a dremel

And the new monster fiberglass cutting wheels - just awesome.

 

[deltaydeltax]

Look at catalog page 71 when it finishes downloading. They have rectangular punches in various sizes. If you're making a lot of enclosures, they are a valuable tool and it takes you a small fraction of the time to get an IEC mounted:

http://www.greenlee.com/cat_docs/Hol...g08_lowrez.pdf

 

[tintin47]

A dremel. Hands down the easiest and cheapest option if you don't intend to do a lot of cases. If you do, a cleaner option would probably be better, but the dremel is still good. That or you can just (carefully) drill holes and use a hacksaw by running the blade through the whole and then attaching it to the handle.

 

[keyid]

for large holes you can use a jiggsaw with metal fine tooth, or invest in a stationary wire saw.

 

[amc]

Quote:

Originally Posted by tintin47 /img/forum/go_quote.gif A dremel. Hands down the easiest and cheapest option if you don't intend to do a lot of cases. If you do, a cleaner option would probably be better, but the dremel is still good. That or you can just (carefully) drill holes and use a hacksaw by running the blade through the whole and then attaching it to the handle.

I was going to get one of the new dremel 400iXPR kits for casework but reviews I read said they have problems with heat severe enough for motor burnout. Someone pointed me to Proxxon tools as a better quality and similar priced product. Anybody have an opinion on the micromot 50

PROXXON

 

[deltaydeltax]

Those tools sure do look cool. I gave up on Dremel when mine started shooting sparks out from its side.

 

[smeggy]

I'll be using my step drill bit followed up with either a dremel or my rotozip with carbide cutters. My case is aluminum so no sparks

I have to cut a bunch of 1" holes in the lid as well as IEC socket etc on the back and also cut out the baseplate to lower it so my boards fit. It's a 2" high case so just a bit too shallow for standoffs and heatsinks together.

 

[amc]

Quote:

Originally Posted by deltaydeltax /img/forum/go_quote.gif Those tools sure do look cool. I gave up on Dremel when mine started shooting sparks out from its side.

I know - they seem less like toys than do the new dremels and they are similarly priced in Canada. I have a Proxxon Micromot 50 on order at a local model shop. When it arrives and I have given it a try I will post a review.