Punching Holes In An Aluminium Project Box

[H₂O]

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.

[notlance]

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

[rowjimmytour]

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

[Chuck]

I do this kind of stuff with a hole saw.

[H₂O]

Thanks for all the input.

Do you need a Var Speed or 1/2" drill - or will a 1/4" Drill work?

[rowjimmytour]

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

[notlance]

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.

[328]

If the step-bit doesn't work, sharks with frickin' laser beams on their heads can be trained to do it.     




My greenlee punches do fine on aluminum, but it is overkill.

[notlance]

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?