RichardAllen Posted February 28, 2010 Share Posted February 28, 2010 Is there an easy way to cut a rectangular hole 19mm x 13mm for a rocker switch in, say 1mm aluminium ? Last time, I marked, drilled and filed and it took quite a time to get a good fit. I did not think of using an old chisel. Any better ideas ? All help gratefully received. Regards Richard PS THis http://ae.rsdelivers.com/product/m10-rectangular-hole-cutter-193x131mm/0600155.aspx is what I have in mind, just cheaper. Quote Link to comment Share on other sites More sharing options...
landmannnn Posted February 28, 2010 Share Posted February 28, 2010 I use a narrow jig saw blade and then tidy up with a dremel. I have got a hand nibbler but as with a chisel I always distort the metal. Quote Link to comment Share on other sites More sharing options...
Off Road Toad Posted March 1, 2010 Share Posted March 1, 2010 a Dremmel style multi tool is superb, thats what we use for fitting switches to customers cars. Steve Quote Link to comment Share on other sites More sharing options...
tychoS Posted March 1, 2010 Share Posted March 1, 2010 Is there an easy way to cut a rectangular hole 19mm x 13mm for a rocker switch in, say 1mm aluminium ? Last time, I marked, drilled and filed and it took quite a time to get a good fit. I did not think of using an old chisel. Any better ideas ? All help gratefully received. Regards Richard PS THis http://ae.rsdelivers.com/product/m10-rectangular-hole-cutter-193x131mm/0600155.aspx is what I have in mind, just cheaper. You use a drill made for drilling square holes of course ,-) http://bbs.homeshopmachinist.net/showthread.php?t=92&page=4 The Math behind the drill, the "Reuleaux triangle" http://en.wikipedia.org/wiki/Reuleaux_triangle As for a quick, dirty and cheap approach for drilling one or a few holes in thin aluminium that does not have to be super perfect, I use ordinary round drills and small files. Quote Link to comment Share on other sites More sharing options...
PS_Bond Posted March 2, 2010 Share Posted March 2, 2010 I use a jeweller's piercing saw for obnoxious shaped (i.e. anything not round) cutouts these days. Quote Link to comment Share on other sites More sharing options...
FridgeFreezer Posted March 2, 2010 Share Posted March 2, 2010 I use a square drill bit Quote Link to comment Share on other sites More sharing options...
combivan Posted March 8, 2010 Share Posted March 8, 2010 I'd drill a hole and use a Square Sheet Metal Punch Quote Link to comment Share on other sites More sharing options...
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