Cutting hole in Stainless sheet

[Marctrees]

Need to cut rectangular holes in about 24Ga Stainless sheet.

About 2" x 7", radiused corners OK.

The final hole needs to look nice, not necessarily PERFECT, but it will not be hidden in any way.

Needs to look as close to "factory" made as possible.

But ------------ not in a flat piece.

Picture in your mind - You go to Big Box and buy a typical Stainless sink that mounts old style manner w the rim flange sitting on top of your countertop.

And you want to cutout this hole in like an "overflow" position, near the mounting flange.

So, that flange sticking "up" when you're making the hole, is kinda in the way of some tools.

Best I can figure so far, a Unibit for the 4 corners, sabre saw for straights, cleanup w 5" pneumatic disc sander, and ?something? smaller to clean up the 2" cuts.

BUT even with patience, going slow, I know, if I did quantity's, they would not all be visually acceptable.

I MAY need to do this just once , but I'm posting BECAUSE very possibly hundreds of times, so need efficient methods.

Thank you all, Marc

 

[kkroger]

Drill a couple holes of appropriate size and use square chassis punches...

 

[DieselO]

I have used a jig saw with tape along the bottom guide plate not to scratch the stainless. Used this method on a fire truck worked perfect for 10" circle.

 

[Crusarius]

Sheet metal nibbler. or punch. or mill.

The nibbler probably be the quickest unless you can find the right size punch and have a decent press.

If you use a punch and have a proper size press you can actually have a tool made with dimpled edge to give it a real nice finish.

 

[yaidunno]

A sharp pair of tin snips should be able to handle 24 ga SS. Make your initial cut 1/8-3/16" smaller in each direction. Then finish it out by trimming the small strip around the perimeter.

A hand held nibbler could also be used. Depending on the style of nibbler, a wooden jig could be made to clamp onto the piece and you would simply follow the cutout. This would get you accurate and repeatable results.

 

[EdT]

Profile nibbler like a HECK Trace A Punch. I think that would do it if you can find someone who has one and depending how tall the flange is. The flange height may make punching the hole a challenge as well.

 

[chrism0107]

I am thinking this is an excuse to spend a lot of money on a cnc controlled water jet cutter. All kidding aside as others suggested time and tin snips unless you have a friend that has a plasma cutter

 

[mopar65]

my vote is a plasma cutter.my miller does a very nice job on stainless

 

[bb_max]

Cutoff wheel on an air tool

 

[Prototyper]

+1 for a plasma cutter! I have a Hypertherm, and make extensive use of 1/4" plywood templates. For hundreds of cutouts, definitely would want to make an aluminum/steel template. A hole that size would take 1 min to locate/fasten template with tape or clamp, 15 seconds to cut and 2-3 minutes to cleanup with flap wheel. No easier way to get it done!

 

[Marctrees]

Thanks All, some great ideas. Marc