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Cutting nice holes in rack enclosures

Discussion in 'Hobby Electronics' started by David Findlay, Jul 26, 2009.

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  1. 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,

  2. Jasen Betts

    Jasen Betts Guest

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

    Eeyore Guest

    Punch and die is the best way.

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