Cutting nice holes in rack enclosures

[David Findlay]

I've bought a Jaycar 2U metal rack enclosure for an amplifier project I'm
building. What's the best way to cut nice clean holes in it for the
switches and sockets that are going on it? Also I need to cut some
ventilation slots front and rear, any suggestions? Thanks,

David

 

[Jasen Betts]

Drill hole(s) and file them out square, for neat round holes, you can
drill the hole slightly smaller than needed and then ream it out to
size.

If you're loaded (with money) square drills can be had

If you want to do vent slots in ALUMINIUM, a router can be used, be
very careful and take it slowly, you will be surprised at how well it
cuts.

yeah, tungsten carbide woodworking tools cut aluminium really well,
the aluminium is soft and conducts heat well enough that the tool doesn't
overheat. tends to get noisy though.

If you are happy with a round ventilation hole for (say) a fan, you
can use a hole saw at a slow speed, or a jig-saw with a suitable metal
cutting blade.

hole saws tend to slop when used on sheetmetal and you get a knife-edge.
A drill-press or backing block attached to the work could help.

offset aviation snips are great for round holes in thin-enough sheet down
to about 75mm diameter, but a cheap jigsaw will cost less (noisy though).

power-nibblers can be had too, either self-contasined or as a drill
attachment.

 

[Eeyore]

I've bought a Jaycar 2U metal rack enclosure for an amplifier project I'm
building. What's the best way to cut nice clean holes in it for the
switches and sockets that are going on it? Also I need to cut some
ventilation slots front and rear, any suggestions?

Punch and die is the best way.

Graham