cutting holes

[MACHINE MEDIA]

> Will a nibbler work on 1/8" aluminum?

If you are referring to the typical hand powered nibbler sold by GC 
Electronics (GC was to TV repairman what Snap On is to engine mechanics) 
it will cut up to 18 ga. steel and 1/16" copper, aluminum or plastic.  
However, the term nibbler can also refer to the power tool used by 
welders to cut sheet steel -- in this case it would cut 1/8" alumininum 
but might stick and warp the sheet because aluminum is alot softer than 
steel.

If you really want to get whole hog into chassis building the tool you 
want is called a punch (eg. slug buster) that works with a ratchet or 
hydraulic driver.  You drill a pilot hole, assemble the punch to go on 
both sides of the metal, and crank it up until it breaks through.  There 
are punch sets that can go through even heavy steel and fiberglass.  
Small round punches (ie. they make circular holes) for 20 gauge steel are 
around $20 each, while more exotic shapes like D-connectors and large 
meter holes can go for several hundred dollars per punch.

A more cost effective solution for dealing with large holes might be a 
hole saw.  That is what I use.  I back up the metal sheet with a piece of 
wood and cut from the inside out.  After that I deburr and touch up the 
hole with a file or dremel tool.  This isn't the most elegant solution, 
but it does work.

Anyone have any ideas on how to cut rectangular holes for IEC connectors??

PEACE OUT :)
MARK