Make large rectangle holes in 1.6mm steel chassis?

[Speedypancake]

Hi - I'm eyeing up a blank 1.6mm steel chassis for my next project. I already have a 50W transformer set, but they are the drop through / lay flat type and would need some fairly large rectangle holes to be cut out the chassis @80mm X 70mm.

Short of metal jig saw or angle grinder!.. how would you create these holes?

Thanks

[ChopSauce]

Short of jig saw? Buy one!

You can drill (then file) all along the edge but what a pain - and risk - for sparing the cost of such a usefull tool as a jig saw.

No friend to let you use his own?

[TUBEDUDE]

I either drill the corners and insert a coping saw with a meal blade, or Dremel with a cutoff wheel. But I use aluminum chassis. With thick steel, I'd find a water jet or laser service. Short of that, your biggest chassis punch, then file work till your hands cramp and bleed.

[Speedypancake]

OK - thanks guys, jig saw it is!
Was just checking first incase there was some special tool / punch I didn't know about
Cheers

[ChopSauce]

Yes, you sould drill the corners first, and of course 1.6mm steel is not that easy to cut but a jig saw should handle that, provided you have a good blade. NB I use cutoff wheels for thin sheets, mostly, because the strength of the jig saw make them warp badly.

Numerically operated punches should be able to do that better, but you're better buy a genuine Dumble than one of those ...

[alkuz1961]

Of course, metal with a thickness of 1.6 mm is quite difficult to process, but for a slightly thinner metal, such a tool is very convenient

this cuts very smoothly, without deforming the edges and allows you to make a curly line

[thetragichero]

just purchased a chassis nibbler after a long time of drilling the perimeter. an absolute revelation!

[dorrisant]

That tool looks fantastic.

Can't seem to find it in the states though.

[ChopSauce]

Yes. This tool looks awesome. A revelation ...

How thick a sheet of mild steel / aluminum can you cut with it?

[alkuz1961]

How thick a sheet of mild steel / aluminum can you cut with it?

[ChopSauce]

How thick a sheet of mild steel / aluminum can you cut with it?

2021-03-28_15-41-12.jpg

Oh yes, thanks. I own one of these. The tool posted by thetragichero, however, seems more capable, but how much?

[Phil_S]

Short of a proper punch or laser cutting, none of these methods will be 100% perfect. You don't need perfect, but you should temper your expectations. For 1.6mm steel, I think I'd go for Dremel with a cut off wheel, and cut just shy of the cut line. Then finish with a file. Drilling the corners is a good idea. I think I'd allow 30-60 minutes so to do this. It's best not to hurry.

[ChopSauce]

I wouldn't proceed without drilling the corners first.

[gtomax]

I second the drill + nibbler combo, it works a treat.

If you're working with very stubborn material a saw would be better. I would avoid the cutoff wheel route, too much potential to shatter the cut wheel and cause serious personal injury.

[Phil_S]

I have done this with a hacksaw blade and file, but with mediocre results. I don't like the jig saw because a) it tends to wander and 2) it doesn't do so well with the unsupported material. What other sort of saw could be used? This is why I suggested the Dremel. Maybe with 1.6mm material, the jig saw is OK?