Easiest way to make holes in control panel

[liche]

Just wanted to know what our easiest way to make holes in a metal control panel is.  I'm not about to shell about $300.00 for a hydraulic panel punch and I have far too little patience to use my scroll saw to cut these holes out.

Thanks
L

[Keith O]

I just finished my metal panel. I used a titanium bit to drill pilot holes then used a hole saw. Home Depot carried everything I needed - 3/4" hole saw for the joystick shaft holes and 1 1/8" hole saw for the buttons. It was 16 guage steel and it took a little while to drill the holes (and created a lot of heat). The finished hole was not perfect but close enough. Plus, when you put the buttons and joysticks in, the holes are not seen anyway. I'm very pleased with the results.

[rampy]

I use what I like to call a "LA-SER" as part of my Alan Parson's project cabinet...  

rampy

[telengard]

Just wanted to know what our easiest way to make holes in a metal control panel is.  I'm not about to shell about $300.00 for a hydraulic panel punch and I have far too little patience to use my scroll saw to cut these holes out.

Thanks
L

I've made 6 control panels so far (all metal) and your best bet is to buy a 1 1/8" bi/metal hole saw
and stick it in your cordless drill.  I was making so many holes though I bought a cheap drill press.
Use some cutting oil too to speed it up.

good luck

[drabbit]

Bi/metal hole saws do make a great job and I would recommend using this for large holes like for trackballs. But I would also recommend using them only if you have a drill press and the panel is well clamped down.

Another tool that I always use for all my smaller holes like buttons, joysticks and smaller holes like for cariage bolts, is a step drill bit. As seen here http://www.vatool.com/Catalogs/bodytemps/202.asp?PSubName=DRILLING%20PRODUCTS&PSubNum=202&PFamName=SPECIALTY%20DRILLS&PClassNum=2020401&UClassNum=53&UClassName=Titanium%20Coated%20Step%20Drill%20Bit. This one is from Vermont American but many companies make them and you don't need a titanium coated one neither (it was the first link I found). Anyway, this is the only bit that will make perfectly round holes in metal panels, not trianglish rounded holes like most regular drill bits. And with the bits that I have, I can make holes up to 1 1/2 inches big.

[GodSend25]

Totally unrelated, but Rampy, are you a big stormbad fan as well? That guy is sooo funny!

[spidermonkey]

1:  Purchase the bi metal hole saws. You only need three or    four sizes at the most.
2:  Purchase a can of cutting oil and don't be shy with it. Hole saws get hot REAL quick so oil it frequently.
3:  Purchase a small drill press from Home Depot.
4:  Use it to drill all your holes (make sure you choose the right size hole saw because if the hole is not quite big enough you can't just grab the next size up and ream it out as hole saws don't work that way. You only get one shot at the hole.
5:  Check all the hole sizes by placing your buttons,joysticks,spinners ect...into the holes and make sure they fit before you put the drillpress back in the box.
6:  Return the drillpress to Home Depot and tell them that the thing does'nt have enough power to drill through melted butter and you want your money back.Don't worry,they will just put it right back on the shelf and resell it. God knows I've gotten stuff from Home Depot that was broken or missing parts. Its time to get some redemption Probably not the most honest solution but none the less its a solution.

Tip:  Drill test holes in a piece of 1/4"  plywood and place controls in them and check for fit before you commit to the hole saw sizes that you have chosen. Check twice and drill once,measure twice cut once. (tips from my ol' man)  Don't wimp out and build a wood cp. Metal cps rock! and they also don't limit the types of pushbuttons you can use like 3/4" wood does.
Good Luck
S.M.