Cutting holes in metal

[Fat_Trucker]

Hi

I need to cut some holes for buttons in a metal panel above my CP. Its about 3mm thick and I've dried drilling and a holesaw and nothing seems to be making any headway.

Is there a particular tool thats suitable for this?, as at the moment I'm rapidly blunting my cutting tools on it.

Cheers.

[HaRuMaN]

I think what you are looking for is a bi-metal hole saw.  Either that or a Greenlee punch.  A regular hole saw just won't do.

[Samstag]

You'll want to use a drill press for best results.  Otherwise you're going to need a very steady hand.

[jcrouse]

This option may be slightly pricey.

John

[nostrebor]

bi-metal hole saw is the easiest solution. You can cut them handheld as well because they have a pilot bit that guides the saw.

[Fat_Trucker]

Heh, yup thats a major outlay to mount 3 buttons.

Think I might ask around the car repair places locally and see if there's someone who can punch it for me for a drink.

Thanks for the responses chaps.

[Samstag]

This option may be slightly pricey.

John

Yeah, but after cutting those holes you can use it for lots of projects around the house!

My Sherline 5400/2000 is only good for very tiny projects around the house.

[Fat_Trucker]

Bear in mind I have a wife who went absolutely purple because I spent

[terabit]

The bi-metal hole saw works great, just make sure you run the drill in reverse to get it started. If not, the teeth will bite into the metal and rip the drill right out of your hands. It happened to me. It will also make a smoother cut if you start in reverse.

[dax]

Here's what I used.  I do not know if I would go through this again:







A friend came over with some equipment he uses to work on plane cockpits.  He thought this carbide circle-cutting bit might work on the metal playfield panel.  We wore that bit down like a cheap suit at a Salvation Army buffet.  I had to break out the grinder to sharpen the bit several times.

[Samstag]

Those circle cutters need a slow rotation rate and lots of patience on metal to prevent overheating.   They work great in a drill press.

[mark shaker]

I agree with the Greenlee Punch.

You drill a sloppy pilot hole, assemble the punch *, and slowly tighten it with a ratchet. It will make a perfectly clean, perfectly round, precisely placed hole.

* It consists of 3 parts, a punch on one side of your stock, a die on the other side of your stock, and a bolt that connects the two through the pilot hole.

   - Mark

[mmmPeanutButter]

I agree with the Greenlee Punch.

I used the Greenlee punch on mine.  Amazing results.  And super easy and quick... 

...but what about the thickness?  3mm?  Seems really thick.  Anybody used a greenlee on something this thick?