Square peg in a Round Hole?

[otokomae]

I'm putting an effect into a new enclosure, and I've realised that the DC converter is SQUARE shaped.  What's the best way to make a square hole in an aluminum enclosure?  I'm using a regular power drill, but I haven't figured out any way to make any other shape than "round" holes in the aluminum.  Maybe I'm just not being very creative, or something.  I certainly don't want to drill a hole and then have to sand it by hand to get it square unless I really have to.  Has anybody come up with a solution to this problem (I can't be the first person here to run up against something like this)?  Does anybody know of a good website on drilling and stuff like that that could help me?  Thanks!!!

[Torchy]

For small square holes I use a set of needle files. Bigger holes I use a "nibbler" tool ... drill a pilot hole then use this to cut the square out.


Just search google for "metal nibbler tool" - about $10.

[otokomae]

Wow, thanks!!!  Problem solved!

[smashinator]

I've never used a nibbler, how do they work?  I mean, what do they actually do (not how do I operate it)?

[Torchy]

Basically the handles when squeezed pull a square shaped shear down thru a square shaped hole, just like a punch & die.  This one is slightly more expensive but does the same job.
http://www.mytoolstore.com/klein/76011b.html

[petemoore]

Cool !!! I could use one of those...

[otokomae]

I'm getting one of these as soon as I can, probably, but I was just wondering, is this how everybody does it, or does anyone have any other suggestions or ways of making a hole for the square DC jack?

[Nasse]

A file perhaps?

Nibbler tool is cheap and versatile, you can use it in many situations. I have used such tool for cutting plastic sheet (I made a custom guitar pickguard and a template for router)

Quess some punch tool sets are available but for occasional hobby work they are just expensive and hard to find. For woodworking there is drill bits that can do square holes :roll:

[thomas2]

Nasse. mikä toi nibbler on suomeksi? mulla olis käyttöä semmoselle, mutta en tiedä millä nimellä sitä kannattais kysellä  :lol:

sorry guys.. i'll try to keep it in english for now on  :lol:

[Nasse]

Nasse. mikä toi nibbler on suomeksi? mulla olis käyttöä semmoselle, mutta en tiedä millä nimellä sitä kannattais kysellä  

Olisikohan "näkertäjä" joskus käytetty nimitys, tällä nimellä eräs peltiseppä kerran neuvoi minua. Joskus niitä on näkynyt isojen rautakauppojen tarjouskoreissa ja toriautoissa, jotka kiertelee pienempiä  paikkakuntia. Laatu ei näissä aina ole kummoinen, minulta katkesi terä kun leikkasin teräslevyä. Alumiiniin ja muoviin toimii hyvin kun ei yritä liikaa.

Veikkaisin että ilmastointiasentajat ja peltisepät tuntee työkalun, jospa tietäisivät mistä moisen löytäisi.