Where to get square holes cut in metal

[Lurchalicious]

Does anyone know who can cut some square holes in small gauge metal?  I have round punches but nothing to make the smaller squares I need.  Wanting a nice clean look to my project box.

[Leann ull]

Dremel

[Lurchalicious]

Anybody have a dremel to spare? 

[LordEoin]

I've never had much luck with cutting metal with a dremel. I've only done it a couple of times and the dremel doesn't sound the same since. I won't use my dremel for anything thicker than biscuit tins any more.
but if you take your time and don't expect too much from it you should be fine. Keep it on high speed and don't put much pressure on the cutting disc (which you will replace multiple times even on a small job)

[Will_D]

Where are you?

I assume you want small holes for square rocker switches/pids/displays etc

You need to find a small engineering company who know what a "Fly Press" is.

A fly press will punch out various sized rectangular/square holes.

At the other end find a laser cutting company to laser cut the front pannel. Believe it or not laser cutting is not that expensive (ok not cheap//free either but what is)

[Will_D]

Oh and before anyone else asks its one tool I don't have!

[Shanna]

Does anyone know who can cut some square holes in small gauge metal?  I have round punches but nothing to make the smaller squares I need.  Wanting a nice clean look to my project box.

How small are the holes? Could they be done with either a hacksaw blade by hand or else with an electric jigsaw? Dremel is really only for very light stuff imho.

Shanna

[Lurchalicious]

20x27mm and the other is a 20x20mm square

[Lurchalicious]

I have a small hacksaw blade but getting it into the hole is the problem. 

[Lurchalicious]

It's current state...


And since I'm taking pictures..  I made a semi portable electric kettle

[Lurchalicious]

Where are you?

I assume you want small holes for square rocker switches/pids/displays etc

You need to find a small engineering company who know what a "Fly Press" is.

A fly press will punch out various sized rectangular/square holes.

At the other end find a laser cutting company to laser cut the front pannel. Believe it or not laser cutting is not that expensive (ok not cheap//free either but what is)

I'm in booterstown area,   know any laser table shops?

[Shanna]

I have a electric jigsaw and a few drills. You could drill a few pilot holes with a drill to start you off and then you a hand hacksaw to cut the remainder of the holes.

Shanna

[johnrm]

Deburr with a file.

[molc]

I did all my square holes with a drill and jigsaw. Measure 3 times!

[Lurchalicious]

I have a electric jigsaw and a few drills. You could drill a few pilot holes with a drill to start you off and then you a hand hacksaw to cut the remainder of the holes.

Shanna

Jigsaw sounds like a plan to me.  My hand hacksaw has been shit.