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.
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)
Quote from: mshilarious on March 09, 2010, 05:55:08 PM
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)
I do this kind of stuff with a hole saw.
Thanks for all the input.
Do you need a Var Speed or 1/2" drill - or will a 1/4" Drill work?
Quote from: H2O on March 10, 2010, 09:11:18 AM
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 ;)
Quote from: H2O on March 10, 2010, 09:11:18 AM
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.
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.
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?