How to make a "D" hole?
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OccupantRJ
Well-known member
Edm.
383 240z
Well-known member
Greenlee D hole punch.
EdT
Well-known member
Your description is a little vague, but I assume you want to make a "D" hole in a piece of metal or plastic. It's not an easy thing to do. Perhaps the simplest way is to make a round hole and then fill up half of it with a piece of round stock cut in half. The separate piece can be welded, brazed, soldered, glued into the round hole and you'll have a "D" hole.
Will be in plastic, likely UHMW. Bout 1/2" thick. I'll most likely just put a set screw or 2 on the d side. But it would be cool to make a D. I have heard of using a broach to do this, but can't imagine how that could stay on center?
kazlx
Well-known member
Jigsaw and/or router
kazlx
Well-known member
Missed the 1/4 diameter. I'd just drill a pilot hole and use a dremel with the drywall cone thing, basically a mini router.
Yeah, or make a template out of something thin and mini router it a little at a time?
PugetDude
ALLIANCE MEMBER
Dremel in a plunge router base with the smallest straight cut bit you can find- dental tool, maybe?
Superbec
Well-known member
drill and file , it should be really easy in plastic..
AJ.
Well-known member
Coping saw.
Cheers Andrew
Cheers Andrew
MP&C
Well-known member
Broach should be self-centering..
This collet was made specifically for turning 3/4 square stock in making tooling for my Lennox Nibbler.
This collet was made specifically for turning 3/4 square stock in making tooling for my Lennox Nibbler.
oldironfarmer
Well-known member
Ummm, no. You didn't "stump the journal" five hours. You even got some excellent answers but failed to notice.
The very first response was on target with your description: EDM
Later, when you mentioned plastic, you received the answer: Broaching
Broaching is the way to go but it is difficult to make a broach.
Depending on the plastic, you could make a few guided punches.
You failed to give the dimensions of the hole other than 1/4", so let's say the D will contain a 3/16" round hole. You drill a 3/16" hole, then machine a partial D shape, from a 13/64 round with more flat cut off than you want finished. You guide the tool through the hole and skim out part of the plastic. Then go to a 7/32, then 15/64, the 1/4 with the final shape.
You failed to say whether this mysterious hole was to be a blind hold. For a blind hole you do the same but relieve the inside of the tool to collect the waste material then manually clean out the bottom with a mini router.
Stump us with something hard.
dr_clyde
Well-known member
If its not attached to anything, and is portable, I'd cut it on the waterjet. That's a pretty simple job, doesn't require any special broaches or anything.
The 2 waterjet shops I deal with would charge me maybe $50? I bet it would take 10 min to set up, 2 min to cut, barely even need to use garnet.
The 2 waterjet shops I deal with would charge me maybe $50? I bet it would take 10 min to set up, 2 min to cut, barely even need to use garnet.
oldironfarmer
Well-known member
It occurred to me you are trying to make an appliance knob.
Two options: Search the internet and buy one.
Do like a lot of knob manufacturers do, drill a hole put a stub shaft into the hole with the flat on it, then press a small steel plate alongside the flat, embedding it in the plastic.
Two options: Search the internet and buy one.
Do like a lot of knob manufacturers do, drill a hole put a stub shaft into the hole with the flat on it, then press a small steel plate alongside the flat, embedding it in the plastic.
Coping saw is a good one.
Filing UHMW kinda *****, especially a 1/2" thick small hole.
You never said how many holes? Quantity makes a huge difference in the process.
EDIT: just read Iron Farmers post. UHMW for a knob would be a bad choice IMO.
Filing UHMW kinda *****, especially a 1/2" thick small hole.
You never said how many holes? Quantity makes a huge difference in the process.
EDIT: just read Iron Farmers post. UHMW for a knob would be a bad choice IMO.
creativecars
Well-known member
Create a shaft like you need out of some 1/4 stock and grind your flat into it to make the 'D'.
Use a torch to heat your newly created tool red hot and push it into the plastic. It might be best to drill an 1/8" hole as a pilot.
Use a torch to heat your newly created tool red hot and push it into the plastic. It might be best to drill an 1/8" hole as a pilot.
APEowner
Well-known member
Rotary or conventional broach, water jet, press a heated pin into an undersized round bore, drill a round hole and insert a tube with a 'D' hole into it. You didn't give anywhere near enough information to get a real answer.
ovrrdrive
Well-known member
bend some sheet metal into the shape, heat it and burn through. Or use a rotozip and a few guides. It would be a lot easier to make the whole thing out of metal. At least with the tools I have available to me.
Chateau Slate 66
Well-known member
Two pages and still no "A" hole jokes???
I'm disappointed.
I'm disappointed.
4 FN 27
ALLIANCE MEMBER
Two pages and still no "A" hole jokes???
I'm disappointed.
I was just contemplating going there...****...LOL...
For me I would Laser it if I do not have that punch in stock for the Turret Press. Either way my media of choice is metal.
Two pages and still no "A" hole jokes???
I'm disappointed.
You mean D-hole!
Punching 1/2" thick UHMW!
Handyfarmer
Well-known member
form a piece of steel in the shape you want heat it and melt it through or in to the plastic.
Jim Johnstone
Well-known member
Use a lathe tool bit in a milling machine and broach it in.
APEowner
Well-known member
Are you testing a knob or a control of some sort that usually has a knob on it?
Testing a new version of http://www.hesinnovations.com/en/site/hesinnovations/products/cabinet-locks/k100/
56Mark
Well-known member
3D print. I make parts at work on 3D printer that should be strong enough for this. Resin material similar to ABS.
Might be the best reply yet. Have a diminsion sst and a maker bot. But want to use UHMW to not mar test samples. The first reply of edm is the best, but tring to keep procees in house.
Thanks all.
Jim Johnstone
Well-known member
The first reply of edm is worthless since it's plastic.
Might be the best reply yet. Have a diminsion sst and a maker bot. But want to use UHMW to not mar test samples. The first reply of edm is the best, but tring to keep procees in house.
Thanks all.
Farrier
Well-known member
Making D holes are tougher than making A holes. I hear B holes can be challenging.
creativecars
Well-known member
I like C holes...
Farrier
Well-known member
I like C holes...
Me too, but they are very expensive