Make large rectangle holes in 1.6mm steel chassis?

[TUBEDUDE]

I haven't had any issues with the Dremel cut off wheels. The thin fragile flat disks yes, but not with the thicker reinforced ones made for metal.

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[Bill Moore]

I had to open a chassis for a larger transformer a while back, so I took it to our local machine shop. I drew out the lines to cut, and they milled it out. I drilled the mounting holes after I got the chassis back, and it wasn't much money!

[ChopSauce]

You're lucky if there is some machine shop around you, but I live downtown and there are almost only banks, real estate agencies and hairdressers - but a few shop selling something to eat - around me.

Maybe with 1.6mm material, the jig saw is OK?

I did that. Even with 1.6mm thick steel, I would be carefull at the edges, managing to have the parts as supported and even clamped as possible.

About cutting disks: I have always been amazed watching some people doing precise cuts with that. I know that works!

For some people it does work very well, really, but it's just not for me - yet I sometimes manage to improve my skills doing that, when working on non critical parts.

[TUBEDUDE]

This dremel accessory simplifies cuts.

[ChopSauce]

I have the same. I only use it to cut my tack welds needing to be redone - generally parts to be re-positionned for the weld tend to pull them out of place, when the metal turns back to cold.

[Stephen1966]

+1 for the Dremel (and a step drill at the corners). Just done a 2mm aluminium chassis like that.

Stephen