[sdiy] DIY panel - rectangle hole

[Scott]

Thanks for the replies.  
I'd like to do it myself is possible, but I haven't thought to look into
a local machine shop.  The Schafer prices are for painting and
silkscreening and all.  I don't need that to be done, so maybe a local
shop to simply cut the aluminum will be much less expensive.  I can put
the labels and all on the panel myself.  I've been using clear laserjet
adheasive paper.  Once it's printed, put on the panel and coated w/
lacquer, the paper becomes completely transparent, and unless you look
very closely, it looks like the text is right on the aluminum.  

I don't know of any local machine shops, but I guess that is what t he
phonebook is for.

Thanks again for all the replies Ive gotten.

-----Original Message-----
From: synth-diy-bounces at dropmix.xs4all.nl
[mailto:synth-diy-bounces at dropmix.xs4all.nl] On Behalf Of Veronica
Merryfield
Sent: Monday, August 13, 2007 2:29 PM
To: synth-diy at dropmix.xs4all.nl
Subject: Re: [sdiy] DIY panel - rectangle hole

Scott

You can get punches for some sizes of hole (square, rectangles and so
on) 
but they can be expensive if available. These are two part devices
requiring 
a hole first through which a treaded portion passes to join the punch
and 
anvil parts and a spanner/wrench is used to tighten it thereby
'punching' 
the hole.

There is also a device called a broach that is used for making square
holes. 
This is like a file but with smooth sides and back with the teeth
projection 
being tappered, but again, these come in stock sizes and might be
pricey. 
These normal get used with a press of some sort.

You can do this by hand with the aid of the drill press.

You need a steel rule and an engineers square, drills and drill press, a

hacksaw, a vice and a coupld of files - all relatively cheap handtools.

I assume the panel has straight edges, which are parallel and square 
corners.

Using the square and ruler, you should be able to acurately locate the 
rectangles you need to cut out. I would use a scribe to mark the
perimeter 
but you could use something else providing it won't rub off.

Using the drill press and say a 1/4" drill, drill the first holes in the

corners just touching both adjucent edges. Then drill a line of hole
just 
touching the perimeter and with some care, just touching or a mm away
from 
the previous hole. Take your time. This is called chain drilling.

Once all the lines are done, use around a 1/2" drill to drill just
inside 
the 1/4" holes trying to touch the 1/4" holes in such a way that you'll
be 
able to push out the remaining inner panel. If you can't do this, if you
can 
at least do it once for each line, this will allow you to get a hacksaw 
blade in and enable you to saw though the line of holes.

Now to the filing. Put the panel in the vice using soft jaws or bits of 
wood. Carefully file the lines of holes down to the lines. This will
take a 
while, but with care, you'll be fine. When you get the line done, with
the 
file through the panel, draw the file back and forth along the line
keeping 
the file perpendicular to the panel - this will put a nice finish on the
cut 
out. You could finsh with emery cloth if desired, but the draw finish
from a 
fine file will be ok.

Failing all this, a local machine shop can mill the openings in a short 
space of time.

Hope this helps.

----- Original Message ----- 
From: Scott
To: synth-diy at dropmix.xs4all.nl
Sent: Monday, August 13, 2007 11:58 AM
Subject: [sdiy] DIY panel - rectangle hole


Hello
I'm wanting to drill out my own panel for a project I'm working on, the
midibox sequencer. (yes,I feel like I'm cheating by going to a digital
solution, but all the talk about the PSIM several weeks ago got me
thinking that maybe it is ok :)  )
there are two long rectangular displays for this project.  I've got a
drill press, and I've got the whole standard panel mount panel
construction worked out really well.
This one is all PCB mount, and then the panel just sort of screws onto
the PCB w/ all the switches and knobs and LCD's, which means it has to
be much more precise.  I think I cam get all the holes drilled alright,
but I have no idea what to do for the rectangular holes.

Does anyone have any ideas of how I can DIY that, without buying any
expensive equipment?  The only idea I've had so far is to drill it out
all the way across, and then clean it up w/ a file, but I don't think I
have enough skill to do that and have it all straight and square.  I
know they make wood bits for drilling square peg holes, but I don't
think that would work for metal, as it's basically just a chisel w/ a
drill bit in the middle.

I remember reading a while back about something called a nibbler, or
something.  Is that what I need?  And then does that make nice clean
cuts? (I have no idea what a nibbler is, but I have a hard time
believing that it can make good straight cuts if its something that just
removes a small chunk of metal at a time)


Thanks for any ideas!

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