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Homebrew Equipment A place to show, design and discuss the weird and wonderful electronic creations from the hands of individual members. |
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10th Feb 2019, 4:24 pm | #21 |
Octode
Join Date: Feb 2009
Location: Bletchley, Buckinghamshire, UK.
Posts: 1,223
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Re: Using hole punches on die cast boxes
Steve has got his answer (step drill in press) and hopefully a successful outcome.
But I can add that I have used Q-max cutters in diecast boxes for years. Although the circular cutout piece always disintegrates, which is useful because it's easy to clear from the tool afterwards, I don't think I have ever broken a box or lid. I wonder if there is wide variation in the quality of diecast boxes, or at least in the mix of alloys used? Or maybe it depends on how sharp the cutter is? |
10th Feb 2019, 4:33 pm | #22 |
Moderator
Join Date: Mar 2012
Location: Fife, Scotland, UK.
Posts: 22,899
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Re: Using hole punches on die cast boxes
I've used Qmax cutters for D-sub connectors in diecast boxes. Results have varied from nice metal that takes a clean shearing cut to stuff that crumbles and in-between is stuff that radiates tears from the die/punch.
Tapered reamers work nicely in diecast boxes, even the very zinc-y ones. the force is applied outwards, in the plane of the surface being cut. Diecast boxes vary. David
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Can't afford the volcanic island yet, but the plans for my monorail and the goons' uniforms are done |
10th Feb 2019, 5:00 pm | #23 |
Dekatron
Join Date: Feb 2007
Location: Lynton, N. Devon, UK.
Posts: 7,087
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Re: Using hole punches on die cast boxes
I've used Q-Max cutters fine on diecast boxes, Eddystone brand (now Hammond), 3/4" for B9A valveholders and also 9-way 'D' connectors, no problem.
As others have said, the waste, punched-out bit comes out in pieces. But the hole itself has always been fine. |
10th Feb 2019, 5:04 pm | #24 |
Pentode
Join Date: Nov 2018
Location: Freckleton, Lancashire, UK.
Posts: 232
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Re: Using hole punches on die cast boxes
I've used q max cutters and step drills with no problem on die cast boxes and aluminium.
However on thicker materials (2mm) I find the diameter of the hole is slightly different on each side when using a step drill as even they have a small taper. I only use cone drills / reamers for de-burring. Never in 50 years of using q max cutters have I had trouble punching holes in die cast boxes plus I'm still using the same q max punches - must have been well made ! I always use step drills at the minimum speed in my drill press. Regards Tim
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Building and tinkering for over 50 years, from 807's to digital amateur TV. |
10th Feb 2019, 7:08 pm | #25 |
Triode
Join Date: Feb 2019
Location: Battle, East Sussex, UK.
Posts: 22
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Re: Using hole punches on die cast boxes
Last ones I did I cheated and used my CNC mill
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11th Feb 2019, 2:39 pm | #26 |
Rest in Peace
Join Date: Jun 2006
Location: Chard, South Somerset, UK.
Posts: 7,457
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Re: Using hole punches on die cast boxes
Exactly: the constituents of 'die-cast metals' (as per this thread) are not all the same. The following Website tells us quite a lot about die-casting: metals used, mechanical properties, etc.
https://www.dynacast.co.uk/die-cast-metal-properties Al. |
11th Feb 2019, 8:07 pm | #27 |
Heptode
Join Date: May 2015
Location: Bradford, West Yorkshire, UK.
Posts: 512
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Re: Using hole punches on die cast boxes
I spotted them a week ago and bought some.
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worried about the electrons entering the circuit and the smoke leaving Andrew |
11th Feb 2019, 8:09 pm | #28 |
Dekatron
Join Date: Jun 2009
Location: Staffordshire Moorlands, UK.
Posts: 5,273
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Re: Using hole punches on die cast boxes
I have to say I've used q-max punches 20 or 25mm in diecast boxes many times without any problems, and yes the waste bit breaks up.
A hole saw would be better if you're still not sure but it wouldn't bother me.
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Kevin |
12th Feb 2019, 4:39 pm | #29 |
Octode
Join Date: Jul 2004
Location: Dundee, UK.
Posts: 1,813
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Re: Using hole punches on die cast boxes
I've been using Q-max punches on die cast aluminium boxes of various makes, Eddystone, RS, Hammond and possibly others for over 50 years and never had problems with the box cracking. I have a set up to 50mm and I don't think I've had any trouble up to at least 35mm; I'm not sure I've used the biggest ones on die cast boxes.
I don't often use the ordinary hex (Allen) keys but usually 3/8" square drive hex bits and a ratchet handle. As advised in the instructions, adequate greasing of the punch and screw is useful. I have however had reports of curved castings of street lighting lanterns cracking when using screw-up punches but I couldn't be sure of the care/skill/experience of the operator. This was in an attempt to avoid the crude, uncontrolled holes when using a cone drill. Hole saws are effective but less accurate than screw-up punches and if used in a hand drill, the drill must be fitted wth a side handle to avoid serious injury. PMM |
16th Feb 2019, 2:46 pm | #30 |
Hexode
Join Date: Sep 2004
Location: Newcastle upon Tyne, Tyne & Wear, UK.
Posts: 475
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Re: Using hole punches on die cast boxes
Well, I decided after all to try the punch and...success. No damage to the box and nice clean holes.
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16th Feb 2019, 4:04 pm | #31 |
Guest
Posts: n/a
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Re: Using hole punches on die cast boxes
Very nice holes.
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16th Feb 2019, 4:06 pm | #32 |
Octode
Join Date: Dec 2017
Location: Morden, Surrey, UK.
Posts: 1,560
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Re: Using hole punches on die cast boxes
6sl7 / 6sn7?
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16th Feb 2019, 5:55 pm | #33 |
Hexode
Join Date: Sep 2004
Location: Newcastle upon Tyne, Tyne & Wear, UK.
Posts: 475
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Re: Using hole punches on die cast boxes
The box is for one of a pair of mono power amps using 6SL7 and 2x6V6, based on a Dynaco 10w circuit.
It uses a readily available PCB - just search for "Dynaco 6V6/EL84 6SL7/12AX7". |
16th Feb 2019, 7:30 pm | #34 |
Dekatron
Join Date: Apr 2012
Location: Wiltshire, UK.
Posts: 14,007
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Re: Using hole punches on die cast boxes
The trick here is to do the first bore with a cone-cut from one side of the workpiece then follow up with a second bore from the other side. Then your hole - when breached - is equally-chamfered from either side, with the narrowest part being half way through the material.
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