Cutting square/rectangular hole in sheet metal

[AldeanFan]

What is the best way to cut a square or rectangular hole in a piece of sheet metal.

I’m making a filler panel for a stereo install,
I need a 5”x8” piece of sheet metal with a 1-3/4x5-1/4” hole. About 20 gauge metal. I can use either aluminum or steel.

Thanks!

 

[jack stand]

20ga might be thick enough to drill a 3/8" hole in each corner (staying within the future cut out) and using a jig saw with as fine tooth as you can find (teeth per inch) if cutting steel. For aluminum a high tooth count will cause clogged teeth and any wood cutting blade will work.
Try to support your material as close to the cutting action. Drilling a 3/4" hole (hole saw) in a sacrificial piece of 1/2" ply and doing your cutting with the blade in this hole should work pretty well.

 

[Torque&Recoil]

The jig saw is probably the answer. You could also use a pneumatic nibbler. All the ones I am familiar with can handle 20 gauge. Just be sure to clamp a straight edge to the workpiece so the nibbler doesn't wander all over heck. Use a triangle file to square off the corners, if required.

 

[AldeanFan]

Jigsaw seems like a good idea,
I have some scrap plywood I’ll use as a backer and then file for the final fit

 

[NUTTSGT]

Do you have an air saw ?

 

[no704]

Jig saw. Make the smaller hole first. Also have used a dremmal with a cut off wheel. Blue tape for layout and protection from scratches.

 

[Beerhippie]

A circular saw w/wood cutting carbide blade works wonders on aluminum. One of the small cordless models would be ideal for this.

One advantage of the circular saw over jigsaw is an inherently straight cut--and a very clean one.

Just wear some PPE for the hot chips it will throw.

 

[PCustoms]

A circular saw w/wood cutting carbide blade works wonders on aluminum. One of the small cordless models would be ideal for this.

One advantage of the circular saw over jigsaw is an inherently straight cut--and a very clean one.

Just wear some PPE for the hot chips it will throw.

A little tough to cut a 1-3/4x5-1/4 hole with a circular saw...

 

[Beerhippie]

A little tough to cut a 1-3/4x5-1/4 hole with a circular saw...

Gotta read more carefully!

Dremel or equivalent w/cut-off blade is my choice for DIN openings--with very careful lay-out, as DIN openings have very tight tolerances.

 

[VR6ix]

That's a $1-$2 part off a laser table. Yes, plus processing, overhead, minimum order fee, etc, whatever... But that's a $1-$2 part off a laser table. Go make friends with people at local fab shops I'm KW area

If I didn't work at a fab shop and had to make this on a weekend, I would do the same corner drilling mentioned above, then grab an old, worn-down cut-off wheel (smaller Ø) and clamp the metal to some sacrificial wood and sneak-up on the final cut lines, and file-out the corners to square. If freehand isn't good enough, then clamp some 1x1 angle or flatbar on the cut line and run the cutoff wheel against it as a guide/stop to keep the cut straight.

 

[AldeanFan]

Do you have an air saw ?

That’s one of the few tools I don’t have but should. I think my dad has one but he doesn’t lend tools even to me lol

 

[AldeanFan]

That's a $1-$2 part off a laser table. Yes, plus processing, overhead, minimum order fee, etc, whatever... But that's a $1-$2 part off a laser table. Go make friends with people at local fab shops I'm KW area

If I didn't work at a fab shop and had to make this on a weekend, I would do the same corner drilling mentioned above, then grab an old, worn-down cut-off wheel (smaller Ø) and clamp the metal to some sacrificial wood and sneak-up on the final cut lines, and file-out the corners to square. If freehand isn't good enough, then clamp some 1x1 angle or flatbar on the cut line and run the cutoff wheel against it as a guide/stop to keep the cut straight.

I had a friend that worked in a laser cutting shop but he left for a different job two weeks ago

 

[b-dog]

If I had the material, I would use a jig saw. If I had to buy materials, I would just order the part. You're looking at $9-14 +SH depending on material from sendcutsend. Free shipping if you can figure out a couple more parts to buy. 20ga is thin, like, condom thin. I'd suggest going thicker if you're going to mount anything like a radio in that DIN sized hole.

I attached a .txt file. Change the extension to .dxf if you want to use it on sendcutsend or send it to any other service provider (can't upload .dxf files here)

 

[kerrynzl]

What is the best way to cut a square or rectangular hole in a piece of sheet metal.

I’m making a filler panel for a stereo install,
I need a 5”x8” piece of sheet metal with a 1-3/4x5-1/4” hole. About 20 gauge metal. I can use either aluminum or steel.

Thanks!

I've done this many times .
Scribe the shape , and drill the corners.
cut up to the corners using a Dremel [hand file for a neat square corner, and a clean finish]

With aluminium use beeswax on the Dremel wheels.

 

[NUTTSGT]

That’s one of the few tools I don’t have but should. I think my dad has one but he doesn’t lend tools even to me lol

You won't use it alot so you can go fairly cheap on them.. .. if you use it enough to wear it out, then buy a better one.

 

[The Cobbler]

an angle grinder with a cut off blade can do lots of work too