Tool for cutting project front panels - Page 1
Forum section: electronics / beginners

author: aaronsnoswell
author_rank: Contributor
timestamp: October 07, 2013, 03:48:43 pm
content: Hi all,I'm working on an ATX power supply conversion project, and I want to cut some holes in the front (metal) panel to mount switches. I've used a drill to make circular holes for LEDs and binding posts, but I now want a square hole for an AC mains switch. Is there some standard tool that people use for cutting front panels like this? I seem to recall Dave once mentioned a 'nibbler' tool or something that can be used for making front panel designs. What should I use to cut metal like this? All I can think of is a Dremmel (which I don't have) or a really fine hacksaw (which I also don't have).Any better suggestions?

author: andtfoot
author_rank: Unknown
timestamp: October 07, 2013, 03:54:41 pm
content: A nibbler (as you mentioned) should be able to handle the job:http://en.wikipedia.org/wiki/NibblerI've used one before on thin sheet steel with pretty neat results.If you get desperate, I've also done something similar by drilling a series of holes along the edge and then hacking away with old side-cutters. It's pretty messy though.

author: Matrix828
author_rank: Contributor
timestamp: October 07, 2013, 03:58:56 pm
content: For a square hole, the best bet would be drilling the largest diameter hole you can where the switch would go, and then filing off the edges till square, or, by using a small hacksaw (usually a few pounds/dollars/etc).I've done exactly what you want to do to one of my old power supplies, but luckily it already had a mains switch.The power supply should have a cables hole at the front that a nice circular hole you could slot a round switch in?On my converted psu, you can see the green switch i put in the cable hole, it fit perfectly and switches it of nicelyHope i helped.EDIT - sorry for the very large photo, not sure how to resize

author: mcotis
author_rank: Newbie
timestamp: October 07, 2013, 04:09:43 pm
content: Between using a file, a nibbler, and the drill, you should have most of the tools you need.Also use some masking tape to protect areas you do not want to be scratched.It will also help give you a guide of how much you have material you have left to remove.

author: Yago
author_rank: Frequent Contributor
timestamp: October 07, 2013, 04:25:48 pm
content: A Dremmel type tool is very handy thing for this kind of modification .Pick up sets of drills/ grinding disks/ cut off disks/etc for cheap too .

author: Smokey
author_rank: Super Contributor
timestamp: October 07, 2013, 09:38:48 pm
content: Dremel tools make ugly holes. Drill + nibbler is the ticket!

author: nanofrog
author_rank: Super Contributor
timestamp: October 07, 2013, 10:02:20 pm
content: Drill, nibbler, then file to clean it up if necessary seems to work the best in my experience. Not expensive tools either, so that's a plus.

author: xstream
author_rank: Newbie
timestamp: October 07, 2013, 10:33:59 pm
content: Quote from: Smokey on October 07, 2013, 09:38:48 pmNot necessarily, if you need a bigger hole to begin with a Dremel with a cutting blade is most likely the best way to go. Of course you would still need a file to finish it but it saves a lot of time and can look good if you double/triple mask tape the surrounding area first to protect it if you slip and don't go to fast.

author: geo_leeman
author_rank: Regular Contributor
timestamp: October 07, 2013, 11:05:28 pm
content: A set of fender punches can be a life-saver as well.

author: Smokey
author_rank: Super Contributor
timestamp: October 07, 2013, 11:23:34 pm
content: I just remembered another good tool for making round holes in a thin sheet metal panel. A step drill. Great for cutting holes for things like BNCs and such. Just keep going till you get to the side you want. Works best on a drill press.

author: drake
author_rank: Newbie
timestamp: October 07, 2013, 11:31:31 pm
content: Amazon has a klien nibbler for a good price.http://www.amazon.com/gp/aw/d/B0000CBJCT/ref=mp_s_a_1_1?qid=1381188579&sr=8-1&pi=AC_SX110_SY165_QL70

author: rastro
author_rank: Frequent Contributor
timestamp: October 07, 2013, 11:40:40 pm
content: For smaller holes like 9-pin D-connectors I use a jeweler saw. I bought a saw and spare blades on ebay for about US$10. delivered.Caveats:- Blades are brittle so spares are a must- Piece should be clamped to avoid torquing the saw blade.- Like a copping saw (woodwork) it has limited reach 3-4 inches.- Must drill a pilot hole- Probably better for aluminum and plastic (can cut PC boards)

author: nanofrog
author_rank: Super Contributor
timestamp: October 07, 2013, 11:48:39 pm
content: Quote from: geo_leeman on October 07, 2013, 11:05:28 pmExcept for an old plier type of tool that made a round hole on eBay, all that came up was Fender guitar related stuff.Can you elaborate?Quote from: rastro on October 07, 2013, 11:40:40 pmCoping saw? Or the one that uses an abrasive string rather than metal blade?Giving me ideas though for a Delta scroll saw I have (great at cutting PCB material, but makes a dusty mess).

author: kizzap
author_rank: Unknown
timestamp: October 08, 2013, 02:42:28 am
content: Quote from: Smokey on October 07, 2013, 09:38:48 pmNot true in the slightest. Dremels are fine tools, it is the end user who makes ugly holes. I have seen people in PC case modifying scene who are able to cut pure straight edges in all sorts of material. (i'm talking not needing to clean up after at all.) It is quite impressive to see.To the OP: you basically have every method there that is cheap and reasonable for someone at home to do, in order of preference I'd go for the nibbler if you have one, then drill/saw, then only a drill, and follow up any of those by cleaning up with a file.-kizzap

author: Psi
author_rank: Super Contributor
timestamp: October 08, 2013, 02:50:41 am
content: 1 Mark out the area to be removed with a markerpen.2 Drill a few holes within this area (to quickly remove the area and to provide a point to get the nibbler in)3 Nibble close to the edges but not over them.4 Use a file on the edges to finish it off and get a smooth edge.You can make any shape hole you want using this technique, and they always come out good.

author: Smokey
author_rank: Super Contributor
timestamp: October 08, 2013, 03:39:16 am
content: Quote from: kizzap on October 08, 2013, 02:42:28 amVery Very Very true.::Hangs his head::Hi everyone... My name is Smokey.... And I make ugly panel cutouts with a dremel...One step at a time....

author: PokemonCookies
author_rank: Newbie
timestamp: October 08, 2013, 05:08:29 am
content: I use a drill then a Dremel with a cutting wheel I use diamond metal discs and if I can't get it done with that I'll use a file and some tin snips.

author: marshallh
author_rank: Unknown
timestamp: October 08, 2013, 05:40:09 am
content: Dremel, drill, step bit, set of die files and good hand coordination. The last one can be only acquired over time and practice.You don't need jigs, but they help for >1 unit. Getting it right the first time is slow and time consuming, but may be worthwhile.

author: ejeffrey
author_rank: Super Contributor
timestamp: October 08, 2013, 05:59:30 am
content: For sheet metal panels you can draw your panel in a CAD tool and use toner transfer to outline your cutouts on the panel. That makes it easier to stay within the lines and get everything lined up nicely.

author: MrAureliusR
author_rank: Unknown
timestamp: October 08, 2013, 07:13:32 am
content: Or look up your local hacker space. Mine has a laser cutter. I'm sure they'd have what you need.

author: david77
author_rank: Frequent Contributor
timestamp: October 08, 2013, 07:33:25 am
content: Make your life easier: Use round switches. Problem solved.Failing that, the drill + file method seems to work best in my experience.

author: vsq
author_rank: Contributor
timestamp: October 08, 2013, 07:51:21 am
content: Quote from: david77 on October 08, 2013, 07:33:25 amOr transparent plastic enclosures with capacitive sensing. No cutouts necessary for displays or buttons.

author: G7PSK
author_rank: Super Contributor
timestamp: October 08, 2013, 07:51:33 am
content: A punch and die, you can get ones that have a bolt through them drill a pilot hole line up the punch and die and tighten the bolt until the metal is cut through.

author: bhilly82
author_rank: Contributor
timestamp: October 08, 2013, 10:42:44 am
content: Look into a roto zip, its a rotary saw. They work great just take your time and they will give you great results. But for a cheaper solution would be the nibbler or a jeweler's hacksaw.

author: geo_leeman
author_rank: Regular Contributor
timestamp: October 08, 2013, 01:12:41 pm
content: Quote from: nanofrog on October 07, 2013, 11:48:39 pmSomething like this:http://www.amazon.com/Steel-Punch-Puching-Tool-Aviation/dp/B001CBRK86Commonly used in aviation and sheet metal shops.

author: Dave Turner
author_rank: Frequent Contributor
timestamp: October 08, 2013, 01:16:09 pm
content: Take a look at "Q-Max cutters" on Google.

author: rastro
author_rank: Frequent Contributor
timestamp: October 08, 2013, 04:58:31 pm
content: Quote from: nanofrog on October 07, 2013, 11:48:39 pmSorry, (copping) the spell checker got the better of me. I was comparing a jewelers saw to a coping saw - both with tooth blades.

author: nanofrog
author_rank: Super Contributor
timestamp: October 08, 2013, 05:39:46 pm
content: Quote from: geo_leeman on October 08, 2013, 01:12:41 pmQuote from: rastro on October 08, 2013, 04:58:31 pmThanks guys.

author: kanurys
author_rank: Contributor
timestamp: October 08, 2013, 11:15:14 pm
content: Quote from: Smokey on October 07, 2013, 11:23:34 pmThis is also my preferred tool. Even a Harbor Freight version is pretty handy and cheap. Yes, cheap, but this isn't as cheap as most of their stuff. You just have to make sure to brace the back side somehow so the metal doesn't deform from pushing on it with the bit.

author: Psi
author_rank: Super Contributor
timestamp: October 09, 2013, 12:14:57 am
content: A nibbler really is the best thing for cutting holes with flat edges.It's the kind of thing you don't realize how awesome it is until you own/use one.

author: Smokey
author_rank: Super Contributor
timestamp: October 09, 2013, 06:48:32 pm
content: Quote from: Psi on October 09, 2013, 12:14:57 amI agree... All Hail Lord Nibbler!!!!

author: rastro
author_rank: Frequent Contributor
timestamp: October 09, 2013, 10:46:48 pm
content: Smokey,That is so funny see "nibblers" picture here. I just got done google shopping for a nibbler and he kept getting in the way.Anyway,Looks like Radio Shack carries one for $11 but they're currently out of stock.

author: aaronsnoswell
author_rank: Contributor
timestamp: October 10, 2013, 05:23:45 pm
content: Thanks all for the amazing suggestions! I'll try and pick up a nibbler and fine hacksaw on eBay.To the person who suggested circular switches - brilliant

author: david77
author_rank: Frequent Contributor
timestamp: October 12, 2013, 11:28:24 pm
content: Quote from: aaronsnoswell on October 10, 2013, 05:23:45 pmThat was not a joke, it's just pragmatism. I avoid rectangular cut-outs when ever I can, they're tedious and time consuming. You can drill 20 holes in the time it takes to nibble/saw/file a rectangular hole.

author: timbarnes
author_rank: Newbie
timestamp: October 13, 2013, 12:20:44 am
content: I just finished a project where the front and rear panels are in 1/8" aluminum. My nibbler won't go quite that thick. I used a step drill for the holes, filing to clean things up (or drilling from both sides).For the big rectangular hole I needed for my display, I used a hole at each corner, and then a jigsaw with a metal cutting blade. It's fast and pretty clean. There's always some filing required as well.tim

author: G7PSK
author_rank: Super Contributor
timestamp: October 13, 2013, 09:43:13 am
content: I use one of these in the workshop.http://www.tool-net.co.uk/p-345502/makita-jn1601.html?gclid=CPrUuc3Bk7oCFcTKtAodgDkAOwAlong with one of these, they make cutting small pieces so much easier.http://www.google.co.uk/imgres?imgurl=http://www.alltoolsdirect.co.uk/ekmps/shops/alltoolsdirect/images/bosch-gsc-16-sheet-metal-shear-256-p.jpg&imgrefurl=http://www.alltoolsdirect.co.uk/bosch-gsc-16-sheet-metal-shear-256-p.asp&h=500&w=500&sz=25&tbnid=i6JEV56BoEfwMM:&tbnh=90&tbnw=90&zoom=1&usg=__YrR26B8pkfusf6W3QkxAJ8GJvgE=&docid=_1wobpUAKCRrFM&sa=X&ei=KGpaUvmdMeKW0AXWuICgCw&ved=0CIABEPUBMAg

author: Zsola
author_rank: Newbie
timestamp: October 13, 2013, 09:48:05 am
content: Quote from: david77 on October 12, 2013, 11:28:24 pmCheck this:http://youtu.be/ALiqAXiTQBg

author: vk3yedotcom
author_rank: Frequent Contributor
timestamp: October 13, 2013, 09:50:31 am
content: If your drill bits don't go big enough a tapered reamer can help for larger holes.Then finish off with a nibbling tool and small file.

author: G7PSK
author_rank: Super Contributor
timestamp: October 13, 2013, 12:42:30 pm
content: Quote from: Zsola on October 13, 2013, 09:48:05 amThis how the geometry of square drilling works works.But if you are really serious about holes in metal cases you have to have one of these.

author: geraldjhg
author_rank: Regular Contributor
timestamp: October 14, 2013, 06:33:25 pm
content: yeahuse round switchessquare ones are a pain