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Gear / Technical Help => Battery Boxes, Preamps, Mixers, ADCs, and Processors => Topic started by: H₂O on March 09, 2010, 04:40:52 PM
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What's the easiest way to punch holes into an aluminum project box?
I need to install 5 XLR's into the side of an aluminum project box.
I have a Dremel and obviously a drill - I'd really hate to hacksaw in 5 XLRs.
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Well the easiest way (not the least expensive) is with a panel punch. Greenlee makes them and they are about $45 or so, if I remember correctly. You need a 23 mm or a 15/16" punch. You can use a 7/8' punch, but you will have to do some filing to get it to fit.
Or you can drill out a 7/8" hole if you have a bit that size. A step bit will work if you can find one big enough to drill a 7/8" hole. Something like this:
http://www.amazon.com/Neiko-Titanium-Drill-Shank-Steps/dp/B000FZ2UOY/ref=sr_1_1?ie=UTF8&s=hi&qid=1268175111&sr=1-1 (http://www.amazon.com/Neiko-Titanium-Drill-Shank-Steps/dp/B000FZ2UOY/ref=sr_1_1?ie=UTF8&s=hi&qid=1268175111&sr=1-1)
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You need a 1" step bit--depending on the XLR, it will be 15/16" or 7/8" hole size. Much better than a punch on aluminum--those work better on light gauge steel.
+1
(http://base0.googlehosted.com/base_media?q=http://www.capitolsupply.com/ImageServer.ashx%3Ft%3Dproduct%26h%3D200%26w%3D200%26imageid%3DCS10093336&size=20&dhm=ed29559c&hl=en)
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I do this kind of stuff with a hole saw.
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Thanks for all the input.
Do you need a Var Speed or 1/2" drill - or will a 1/4" Drill work?
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Thanks for all the input.
Do you need a Var Speed or 1/2" drill - or will a 1/4" Drill work?
How big is the XLR hole? I think for most step bits 7/8" and below a 1/4" will work. It helps to have speed to get a clean cut but more important to clamp project box down good ;)
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Thanks for all the input.
Do you need a Var Speed or 1/2" drill - or will a 1/4" Drill work?
You don't really need variable speed, but most of the time the shank on these step bits will be 3/8", so a 1/4" will probably not work. I suppose you could get some kind of 1/4" to 3/8" adaptor if all you have is a 1/4" drill. Maybe it's time to buy a new drill; 1/4" drills have not been common for about 20 years.
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If the step-bit doesn't work, sharks with frickin' laser beams on their heads can be trained to do it. ;)
(http://t1.gstatic.com/images?q=tbn:xLF5miN_FqGJ9M:http://2.bp.blogspot.com/_ZUXitIQ0g-g/ST6e1CpVmGI/AAAAAAAABpw/prMBYuADWM8/s400/shark.gif)
My greenlee punches do fine on aluminum, but it is overkill.
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Doh! Forgot about the fickin' laser beams! Perhaps Laser Cats will work too? Or maybe the Pen Light Sabre, since your regular Light Sabre is for bigger holes?