Cleanly Cutting Metal for CP Under/Overlay?

[Necro]

Ok, I'm finally there.  Initial demo CP has been tested.  Art is semi-designed.  I now need to get the tools to put together my CP.

But...I've hit an issue.  Based on this old thread (http://forum.arcadecontrols.com/index.php?topic=85827.0) I know what to do...but...

How the heck to I **CLEANLY** cut the sheet metal for the overlay?  Snips don't seem like they'd be clean and a jigsaw definitely won't be straight.  A circular saw is asking for something to shoot out and kill me. 

I have other tools (Rotary Tool and Oscilating Tool) but neither seem appropriate either.

Any suggestions?

[Xiaou2]

Cleanly cutting sheet metal usually involves a metal cutting "Brake".

 You may be able to use a fiberglass cutting wheel on a tablesaw to get a decent result
however.

 If you had no other choice, you could cut it with a jigsaw, then clamp the thing to a
straight edge guide, and use a grinder to remove the excess.

 Do not try to use a dremel.  You would need about 8hrs and 60 cut off discs.
 

[Necro]

Hmmm...ok.  This makes things more complicated.  I'm going to put art over it...so...maybe the washer+bondo option wil provide enough strength.

Or thin plexi.  Didn't want to to the plexi route though.  Might have to.

[bkenobi]

Find a metal shop.  They can cut the CP in about 2 seconds and should only charge you a few $ for the effort.  They will either us a break or a band saw.  Either way, they should remove the sharp edges for you so you don't cut fingers off when playing!   

[ubiquityman]

I'm guessing the traditional non-automated tools are the best choice in this case, but if you are making things in volume, some business have laser cutters that can cut 1/2" steel.

[Necro]

No, nothing large volume.  This is basically an overlay template to provide some support to the holes I'm not using in my metal CPs and to facilitate drilling the CP out. 

It's going to be real thin and is only 24"x6" so...not a big issue cutting through it.  Just want it 'clean' (i.e. straight) more than anything.  I can buff/sand down a sharp edge if needed. 

I guess I'll try to find a metal shop...no idea even where to look for that.

[spystyle]

I made a sheet metal control panel before with all low-tech tools, no lasers or anything space-age

1. A corded jigsaw with appropriate blade can cut the panel out (mine was shaped like a rectangle)

2. Pilot-point drill bits and a corded drill can make the carriage bolt holes

3. A radio chassis punch can cut 1 1/8" holes for buttons and sticks - I used chainsaw lubricant oil when using this.

4. An angle grinder to clean up the edges (maybe)

The punch works like this :







Mine was Greenlee Radio Chassis Punch #730, 1 1/8", I see them on eBay sometimes





(those aren't my pics but mine looked like that)

Working with metal is like 100 times slower than working with wood, but it can be done and it's not hard or expensive

Find a metal shop.  They can cut the CP in about 2 seconds and should only charge you a few $ for the effort...

Hey that's a good idea

Have fun!
Craig

[bkenobi]

Hey that's a good idea

I speak from experience.   

I took an old metal CP that had my LS-30's installed in it to a metal shop and had them cut "mounting plates" to use in my MDF CP.  Basically, they just cut out the joystick area for each stick.  I could have done it myself using the methods listed above, but this cost me ~$10 for 2 plates.  It was more than I wanted to pay for the task, but not enough for me to worry about doing myself.  Mehhh, done is done!   

Oh, and I found out my father-in-law had a band saw set up to cut metal one week, so I could have done it myself if I had known.  Whatever...