How do you punch a square hole?

[Hoagie_one]

I'm gonna need to punch some square holes in my Metal CP for carriage bolts to secure a trackball.  How does one punch clean square holes?

[Thenasty]

drill a hole on the four corners and use a dremel. 

[Hoagie_one]

gotta be an easier way. Do they make square hole punches?

[whammoed]

Holes don't have to be square.  I have had no problem tightening the nuts on carriage bolts with round holes drilled...especially on the trackballs...I remember them (happs and ultimarc) having square holes in them that would lock in the bolt.

[Hoagie_one]

holes on my imperial are circle.  I guess I could drill em and them file em a little.

[NoOne=NBA=]

Do they make square hole punches?

Yes, but you're going to need the press they go in.
A machine shop should be able to do it for you, but the cost would probably be a little steep for the few holes you need.

[Ken Layton]

I use a small square file in metal control panels. Greenlee makes square 'knockout' (a.k.a. "chassis") punches but get out your wallet -- they are expensive!

[1UP]

http://www.directron.com/nibbletool.html

I have one of these nibblers, which work pretty well in thin metal and plastic (1/16" or less).  They're more for case modding, so I'm not sure if this would work on a metal control panel.  Also, probably not useful for carriage bolt holes.

[paigeoliver]

I normally just drill the holes round and then either bang the bolts down with a hammer or screw them until they go down flat.

[Hoagie_one]

I normally just drill the holes round and then either bang the bolts down with a hammer or screw them until they go down flat.

use teh bolt to punch the square then....yeah, i'll prolly go that route

[XtraSmiley]

I normally just drill the holes round and then either bang the bolts down with a hammer or screw them until they go down flat.

use teh bolt to punch the square then....yeah, i'll prolly go that route

How big of a hole do you drill to do this?  Also, please post your results, with pics if possible.  I'm going to be doing this to a Space Duel CP soon and don't want to mess it up.  Thanks.

[sodapopinski]

It depends on the thikness of the material. My last panel I ruined three hole saws, they were designed for steel, but it was thick. Regardless, I was able to pound the carriage bolts down and tighten. You should have no problem.

[RayB]

If it's at all possible to cut an X then you will be able to tighten the bolt down into it creating a square.

[jcrouse]

To answer your question, yes. There are square BROACHES. Any industrial supply house (machine shop supplier) will have access to them.

To offer my opinion, as an ex-tool and die maker, drill them round and then file out the corners with a tiny file. I did 12 holes (a cocktail with three cp's) in 1/16 metal cp's in about 15 minutes. It's very simple.

Good luck,
John

[XtraSmiley]

Cool, thanks man!  Can you just hammer these into the hole?

http://mdmetric.com/dumont/prod3a.html

[GalaxyForce]

idealy the broach should be 'pressed' through,  they are made (usually) of high speed steel, and could shatter if you hammer on them.  I have never used one, that is just my opinion.