Tool for cutting project front panels

[aaronsnoswell]

Hi all,

I'm working on an ATX power supply conversion project, and I want to cut some holes in the front (metal) panel to mount switches. I've used a drill to make circular holes for LEDs and binding posts, but I now want a square hole for an AC mains switch. Is there some standard tool that people use for cutting front panels like this? I seem to recall Dave once mentioned a 'nibbler' tool or something that can be used for making front panel designs. What should I use to cut metal like this? All I can think of is a Dremmel (which I don't have) or a really fine hacksaw (which I also don't have).

Any better suggestions?

[andtfoot]

A nibbler (as you mentioned) should be able to handle the job:
http://en.wikipedia.org/wiki/Nibbler
I've used one before on thin sheet steel with pretty neat results.

If you get desperate, I've also done something similar by drilling a series of holes along the edge and then hacking away with old side-cutters. It's pretty messy though. 

[Matrix828]

For a square hole, the best bet would be drilling the largest diameter hole you can where the switch would go, and then filing off the edges till square, or, by using a small hacksaw (usually a few pounds/dollars/etc).
I've done exactly what you want to do to one of my old power supplies, but luckily it already had a mains switch.
The power supply should have a cables hole at the front that a nice circular hole you could slot a round switch in?
On my converted psu, you can see the green switch i put in the cable hole, it fit perfectly and switches it of nicely 

Hope i helped.
EDIT - sorry for the very large photo, not sure how to resize 

[mcotis]

Between using a file, a nibbler, and the drill, you should have most of the tools you need.
Also use some masking tape to protect areas you do not want to be scratched.
It will also help give you a guide of how much you have material you have left to remove.

[Yago]

A Dremmel type tool is very handy thing for this kind of modification .
Pick up sets of drills/ grinding disks/ cut off disks/etc for cheap too .

[Smokey]

Dremel tools make ugly holes.  Drill + nibbler is the ticket!

[nanofrog]

Drill, nibbler, then file to clean it up if necessary seems to work the best in my experience. Not expensive tools either, so that's a plus.

[xstream]

Dremel tools make ugly holes.

Not necessarily, if you need a bigger hole to begin with a Dremel with a cutting blade is most likely the best way to go. Of course you would still need a file to finish it but it saves a lot of time and can look good if you double/triple mask tape the surrounding area first to protect it if you slip and don't go to fast.

[geo_leeman]

A set of fender punches can be a life-saver as well. 

[Smokey]

I just remembered another good tool for making round holes in a thin sheet metal panel.  A step drill.  Great for cutting holes for things like BNCs and such.  Just keep going till you get to the side you want.  Works best on a drill press.

[drake]

Amazon has a klien nibbler for a good price. http://www.amazon.com/gp/aw/d/B0000CBJCT/ref=mp_s_a_1_1?qid=1381188579&sr=8-1&pi=AC_SX110_SY165_QL70

[rastro]

For smaller holes like 9-pin D-connectors I use a jeweler saw.  I bought a saw and spare blades on ebay for about US$10. delivered.

Caveats:
- Blades are brittle so spares are a must
- Piece should be clamped to avoid torquing the saw blade.
- Like a copping saw (woodwork) it has limited reach 3-4 inches.
- Must drill a pilot hole
- Probably better for aluminum and plastic (can cut PC boards)

[nanofrog]

A set of fender punches can be a life-saver as well.

Except for an old plier type of tool that made a round hole on eBay, all that came up was Fender guitar related stuff.

Can you elaborate?

For smaller holes like 9-pin D-connectors I use a jeweler saw.  I bought a saw and spare blades on ebay for about US$10. delivered.

Caveats:
- Blades are brittle so spares are a must
- Piece should be clamped to avoid torquing the saw blade.
- Like a copping saw (woodwork) it has limited reach 3-4 inches.
- Must drill a pilot hole
- Probably better for aluminum and plastic (can cut PC boards)

Coping saw? Or the one that uses an abrasive string rather than metal blade?

Giving me ideas though for a Delta scroll saw I have (great at cutting PCB material, but makes a dusty mess).

[kizzap]

Dremel tools make ugly holes.  Drill + nibbler is the ticket!

Not true in the slightest. Dremels are fine tools, it is the end user who makes ugly holes. I have seen people in PC case modifying scene who are able to cut pure straight edges in all sorts of material. (i'm talking not needing to clean up after at all.) It is quite impressive to see.

To the OP: you basically have every method there that is cheap and reasonable for someone at home to do, in order of preference I'd go for the nibbler if you have one, then drill/saw, then only a drill, and follow up any of those by cleaning up with a file.

-kizzap

[Psi]

1 Mark out the area to be removed with a markerpen.
2 Drill a few holes within this area (to quickly remove the area and to provide a point to get the nibbler in)
3 Nibble close to the edges but not over them.
4 Use a file on the edges to finish it off and get a smooth edge.

You can make any shape hole you want using this technique, and they always come out good.

[Smokey]

Dremel tools make ugly holes.  Drill + nibbler is the ticket!

Not true in the slightest. Dremels are fine tools, it is the end user who makes ugly holes. I have seen people in PC case modifying scene who are able to cut pure straight edges in all sorts of material. (i'm talking not needing to clean up after at all.) It is quite impressive to see.
To the OP: you basically have every method there that is cheap and reasonable for someone at home to do, in order of preference I'd go for the nibbler if you have one, then drill/saw, then only a drill, and follow up any of those by cleaning up with a file.
-kizzap

Very Very Very true.   
::Hangs his head::

Hi everyone... My name is Smokey.... And I make ugly panel cutouts with a dremel...

One step at a time....

[PokemonCookies]

I use a drill then a Dremel with a cutting wheel I use diamond metal discs and if I can't get it done with that I'll use a file and some tin snips.

[marshallh]

Dremel, drill, step bit, set of die files and good hand coordination. The last one can be only acquired over time and practice.
You don't need jigs, but they help for >1 unit. Getting it right the first time is slow and time consuming, but may be worthwhile.

[ejeffrey]

For sheet metal panels you can draw your panel in a CAD tool and use toner transfer to outline your cutouts on the panel.  That makes it easier to stay within the lines and get everything lined up nicely.

[MrAureliusR]

Or look up your local hacker space. Mine has a laser cutter. I'm sure they'd have what you need.

[david77]

Make your life easier: Use round switches. Problem solved.

Failing that, the drill + file method seems to work best in my experience.

[vsq]

Make your life easier: Use round switches. Problem solved.

Or transparent plastic enclosures with capacitive sensing. No cutouts necessary for displays or buttons.   

[G7PSK]

A punch and die, you can get ones that have a bolt through them drill a pilot hole line up the punch and die and tighten the bolt until the metal is cut through.

[bhilly82]

Look into a roto zip,  its a rotary saw.   They work great just take your time and they will give you great results.  But for a cheaper solution would be the nibbler or a jeweler's hacksaw.   

[geo_leeman]

A set of fender punches can be a life-saver as well.

Except for an old plier type of tool that made a round hole on eBay, all that came up was Fender guitar related stuff.

Can you elaborate?

Something like this: http://www.amazon.com/Steel-Punch-Puching-Tool-Aviation/dp/B001CBRK86

Commonly used in aviation and sheet metal shops.

[Dave Turner]

Take a look at "Q-Max cutters"  on Google.

[rastro]

A set of fender punches can be a life-saver as well.

Can you elaborate?

Coping saw? Or the one that uses an abrasive string rather than metal blade?

Giving me ideas though for a Delta scroll saw I have (great at cutting PCB material, but makes a dusty mess).

Sorry, (copping) the spell checker got the better of me.  I was comparing a jewelers saw to a coping saw - both with tooth blades. 

[nanofrog]

Something like this: http://www.amazon.com/Steel-Punch-Puching-Tool-Aviation/dp/B001CBRK86

Sorry, (copping) the spell checker got the better of me.  I was comparing a jewelers saw to a coping saw - both with tooth blades.

Thanks guys. 

[kanurys]

I just remembered another good tool for making round holes in a thin sheet metal panel.  A step drill.  Great for cutting holes for things like BNCs and such.  Just keep going till you get to the side you want.  Works best on a drill press.

This is also my preferred tool. Even a Harbor Freight version is pretty handy and cheap. Yes, cheap, but this isn't as cheap as most of their stuff. You just have to make sure to brace the back side somehow so the metal doesn't deform from pushing on it with the bit.

[Psi]

A nibbler really is the best thing for cutting holes with flat edges.
It's the kind of thing you don't realize how awesome it is until you own/use one.

[Smokey]

A nibbler really is the best thing......

I agree... All Hail Lord Nibbler!!!!

[rastro]

Smokey,
That is so funny see "nibblers" picture here.  I just got done google shopping for a nibbler and he kept getting in the way. 

Anyway,
Looks like Radio Shack carries one for $11 but they're currently out of stock.

[aaronsnoswell]

Thanks all for the amazing suggestions! I'll try and pick up a nibbler and fine hacksaw on eBay.

To the person who suggested circular switches - brilliant

[david77]

To the person who suggested circular switches - brilliant

That was not a joke, it's just pragmatism. I avoid rectangular cut-outs when ever I can, they're tedious and time consuming. You can drill 20 holes in the time it takes to nibble/saw/file a rectangular hole.

[timbarnes]

I just finished a project where the front and rear panels are in 1/8" aluminum. My nibbler won't go quite that thick. I used a step drill for the holes, filing to clean things up (or drilling from both sides).

For the big rectangular hole I needed for my display, I used a hole at each corner, and then a jigsaw with a metal cutting blade. It's fast and pretty clean.  There's always some filing required as well.

tim

[G7PSK]

I use one of these in the workshop.

http://www.tool-net.co.uk/p-345502/makita-jn1601.html?gclid=CPrUuc3Bk7oCFcTKtAodgDkAOw

Along with one of these, they make cutting small pieces so much easier.


 http://www.google.co.uk/imgres?imgurl=http://www.alltoolsdirect.co.uk/ekmps/shops/alltoolsdirect/images/bosch-gsc-16-sheet-metal-shear-256-p.jpg&imgrefurl=http://www.alltoolsdirect.co.uk/bosch-gsc-16-sheet-metal-shear-256-p.asp&h=500&w=500&sz=25&tbnid=i6JEV56BoEfwMM:&tbnh=90&tbnw=90&zoom=1&usg=__YrR26B8pkfusf6W3QkxAJ8GJvgE=&docid=_1wobpUAKCRrFM&sa=X&ei=KGpaUvmdMeKW0AXWuICgCw&ved=0CIABEPUBMAg

[Zsola]

To the person who suggested circular switches - brilliant

That was not a joke, it's just pragmatism. I avoid rectangular cut-outs when ever I can, they're tedious and time consuming. You can drill 20 holes in the time it takes to nibble/saw/file a rectangular hole.

Check this: http://youtu.be/ALiqAXiTQBg

[vk3yedotcom]

If your drill bits don't go big enough a tapered reamer can help for larger holes.

Then finish off with a nibbling tool and small file.

[G7PSK]

To the person who suggested circular switches - brilliant

That was not a joke, it's just pragmatism. I avoid rectangular cut-outs when ever I can, they're tedious and time consuming. You can drill 20 holes in the time it takes to nibble/saw/file a rectangular hole.

Check this: http://youtu.be/ALiqAXiTQBg

This how the geometry  of square drilling works works.



But if you are really serious about holes in metal cases you have to have one of these.

[geraldjhg]

yeah
use round switches
square ones are a pain