[sdiy] DB25 hole

[ASSI]

On Saturday 05 March 2011, David Moylan wrote:
> Anyone made a DB25 shaped hole in a cast aluminum box?  Favorite methods
> or tools?

If you have a drill press and vice (and the box in the vice actually fits 
under the press), then you can make four large holes to define the corners, 
then do a smaller hole in the middle between each orner and then use a 
router to open a slot from the pilot holes to the corners.  If you can clamp 
or screw (through the fastener holes perhaps) a piece of scrap sheet metal 
behind the opening-to-be, that'd save you a good deal of deburring.  If 
you're missing the router bit you can make a few more holes along the 
straight lines after scribing them and take out the rest with a chisel (for 
metal of course).  Make the distance between the holes slightly smaller than 
the width of the chisel (you might skip making the extra holes if you are 
careful).


Achim.
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