cutting holes

[Kevin Lightner]

For what it's worth, here are the methods I've used:

1. Drilling a hole and then using any of the following:

   a. jewelers saw
   b. file assortment (get the right ones!)
   c. rotary grinder with mini die grinder or correct burr

2. Punches. I have only one left, a DB-25 punch, expensive as hell. All
others were sold. (This one is up
    for grabs too!). Greenlee makes all square and round sizes as well as
many rectangular shapes and all
    DB and Centronic or Amphenol style punches.

3. Rotary grinder tool (Dremel, flex shaft or air will do) with a
separating disk or rotary cutter.
    This method is very fast, but also the most dangerous in terms of your
hands, eyes and panel.

4. Professional metal workers. Either a production sheet metal company or a
small lot engraver.
    This one yields the best results. Beautiful, burr-free cuts. Bezeled
edges, complex shapes, etc are usually
    no problem. They can supply the metal, anodize it ANY color and if they
mess up, they are responsible.
    While more expensive, there is something to be said for a great job
that will last a lifetime and one you
    didn't need to make your hands bleed over. Unless, you like that sort
of thing....!
    In the Los Angeles area I use Burbank Sheet Metal, Industrial Metal
Supply or JC Engravers.

You can go pretty far with a good drill and file assortment and some
patience, though.
A good tapered reamer also helps.


Of course when I was twelve, I would buy plastic enclosures and make holes
with a soldering iron!

-Kevin

http://www.leonardo.net/majmoog/synthfool.html