How do I make square holes for bolts in metal control panel?

[rackoon]

Like the title says I need to make square holes in my metal CP so my bolts holding my joystick wont spin when I tighten them. I was hoping to use black bolts with no screw driver notch on them. Should I try a file or may by a carbid blade in my jig saw.

So how is every one else solving this?

[Fozzy The Bear]

Like the title says I need to make square holes in my metal CP so my bolts holding my joystick wont spin when I tighten them. I was hoping to use black bolts with no screw driver notch on them. Should I try a file or may by a carbid blade in my jig saw.

So how is every one else solving this?

Drill a hole then file it out square with a square needle file..... It's really quick and easy to do. Try it.

Best Regards,
Julian (Fozzy The Bear)

[Ken Layton]

Drill a hole and file it out. That's how I have always done it.

[leapinlew]

I recommend Kens method.

I do not recommend Fozzys method.

 

[Fozzy The Bear]

I recommend Kens method.

I do not recommend Fozzys method.

 

ROFL What is this Lew.... "National Confuse a Newbee Day" LOL 

Best Regards,
Julian (Fozzy The Bear)

[ahofle]

I recommend Kens method.

I do not recommend Fozzys method.

 

[FrizzleFried]

Both Ken and Fozzy are NUTS!  Much much too hard to use either of their method!  I have found the best way to do what you are asking is to simply drill a hole and use a square file to file it out.   Cleanest way to do it by far!   

[rlemmon]

Your all nuts ! He needs to go to lowes and get a square drill bit.

[johnm160]

A square router bit is much faster and cleaner. 

[FrizzleFried]

Blow torch?

[Fozzy The Bear]

OK OK I take back my first answer......

The best way to cut these holes is with a "thermal lance" This is a high pressure gas plasma cutter cooled by liquid nitrogen on the end of a 12 foot pole designed for cutting through up to 4" plate steel.... Favoured by large scale safe crackers.  Works like a dream. Even cuts great trackball holes.

Anyway!!! Who says the hole wants to be square... It's Like So Uncool to be square Dady'o...

Best Regards,
Julian (Fozzy The Bear)

[johnm160]

Can I get a cheap one at Harbor Freight?

[rackoon]

I had a feeling you guys were going to say that.

So off to Home Depot it is, to buy a square drill bit 

[johnm160]

Good Choice

[shardian]

Just use your teeth like normal people. Don't listen to these yahoos.

[SirPeale]

Just use your teeth like normal people. Don't listen to these yahoos.

Teeth are jewels, not tools.

[hypernova]

Easy.  Square hole punch.  They have 'em at Staples.   

[bfauska]

This thread is cracking me up, but on a serious note... If you don't want to file your round holes square (which as we've heard several times is the wrong way), or you don't want to start with round holes and make them square with a file (also clearly wrong) you could use a square hole Punch as suggested by Hypernova, only problem there is his source doesn't provide stout enough punches. 

We use Greenlee punches at work for our square holes in steel needs, and I think I have seen people discuss similar products for getting a button sized hole (round) into a metal CP also.  You can use them with just the punch and a wrench.

WARNING, this is a rather large PDF of the catalog, if your not interested in the punch I wouldn't wast the time or bandwidth.
http://www.greenlee.com/cat_docs/Holemaking_07.pdf

Enough serious suggestions, has anybody tried cutting a round hole and filing it?

Later,
Brian

[JustMichael]

Like the title says I need to make square holes in my metal CP so my bolts holding my joystick wont spin when I tighten them. I was hoping to use black bolts with no screw driver notch on them. Should I try a file or may by a carbid blade in my jig saw.

So how is every one else solving this?

If you make a hole all the way through the control panel big enough for the end of the bolt to fit through, won't the bolt just fall right through?