Tool for cutting project front panels

[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