Cutting "D" Shaped Holes?

[kruegdr]

I've run into some electrical parts before that require "D" Shaped holes so the parts don't spin. I've got some Brake lines that need the same shape in a frame tab so they don't spin.

How does one cut them without having a specialty tool?

I was thinking of laying out the pattern, then using small drill bits to drill around the inside of the perimeter then use a file. Is there an easier way?

Thanks,

 

[Alchymist]

Chassis punch.

http://www.e-sonic.com/aboutus/cat/H/hole 2.pdf

Scroll down.

 

[Kevin54]

Buy a Dremel tool. You'll always find uses for it later on down the road. Or buy some various size carbide burrs and use a hand drill although a little awkward.

 

[jeepfan93]

What kind of material? How many holes? About how big? I do this with aluminum fan shrouds. Drill out the 90 degree corners then use a jigsaw. If small holes the a Dremel with carbide bits will work.

 

[lametec]

Plasma cutter.

 

[MoToys]

You could get a greenlee punch they are not too expensive.
Otherwise undercut with a hole saw and hand file the flat edge.

 

[kruegdr]

Thanks for the tips, guys. Wish I had a plasma cutter that could do the small stuff. For now it's a drill and file.

I definitely need a Dremel. Whenever I seem to be in the store with one in front of me, I say, "When would I really use this?" Then of course, I don't get it and run into days like these, lol.

dk

 

[BHR4CE1]

Whenever I seem to be in the store with one in front of me, I say, "When would I really use this?"

Same here, but this post has inspired me to go get one. NOW...which one to get???

 

[nate379]

I use the **** out of my Dremel. It's honestly one of the most used power tools I own.
Never figured that'd be the case, bought it ~10 years ago for some project and been using it since.

 

[Trucky]

I bought an "el cheapo" from Target, a dremel knockoff, for $10 a long time ago. Killed it, bought a 400 XPR, the top-of-the-line at the time, and used the hell out of it. Sold it. Biggest mistake I've made in a while! I like the corded ones with a flex shaft because they're just plain workhorses. I need a "4000" model now. Rather large, but a flex shaft just makes it so easy to do things. I think they're $90... I paid 70 for the 400 XPR, and it was worth it. Very much so.

 

[diesel research]

I say go for the milwaukee cordless m12 rotary....then feel free to add various other stuff to the m12 system.

Corded tools work great (had a corded dremel for years) until the day you either feel like not dragging out the extension cord, or have no outlets anywhere near.