How to cut a square hole in stainless

[radio2000]

I need to cut a square hole, approx 1 1/4", in 1/8" -3/16" stainless. (See below)
Any ideas on the best way to do so?


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[radio2000]

I have a press, would just need the die. Unfortunately, no cnc.
I was thinking drilling the hole then coping saw. Was just hoping for something else.

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[LXCam]

And ^^^. If you’re really really really good with an angle grinder and cut off disc do it from the back side just shy of the cut line and clean it up with a file.

 

[JerryC]

AVE has a video how to do this. He doesn't do it on stainless and I don't know if it matters.
Basically make broaching tool or drill a hole and use a file to square the corners.
Not nearly as fast as a punch, but it works.

 

[radio2000]

AVE?

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[tool_scrounge]

Possible options...

Drill + scroll saw with fine blade + file

Mill + file

Drill + die filer

Whitney no 5 hand punch in stand + filing

Heck industries trace a punch + file

Drill corners + Dremel tool with cutoff blade + file

Drill corners + coping saw + file

 

[PFSard]

AVE?

 

[MushCreek]

My go-to when I don't have a machine shop at my disposal is to drill as big as I can, then finish with a jigsaw with a metal cutting blade and SLOW speed. But this is GJ; time to convince the wife you NEED a wire EDM.

 

[HenryAZ]

Drill holes at each corner, then an angle grinder with cutoff wheel, or a jigsaw with a metal cutting blade to connect the holes. Go slowly with the jig saw. Clean it all up with a file.

 

[MushCreek]

It also depends upon how many pieces you're making. One? A thousand? 43 million?

 

[radio2000]

It also depends upon how many pieces you're making. One? A thousand? 43 million?

Just 1
It's an adapter for my smoker to hold the fan of a flameboss 500.

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[radio2000]

Drill holes at each corner, then an angle grinder with cutoff wheel, or a jigsaw with a metal cutting blade to connect the holes. Go slowly with the jig saw. Clean it all up with a file.

This is what I'm leaning towards right now

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[RTM]

I’d go 4 holes in the corners, connect with the metal cutter at hand, jigsaw or hacksaw. I’m not good enough to use an angle grinder yet. Assuming the fan will cover any errors, so just enough cleanup to prevent damage to you or the fan.

 

[dnschmidt]

Best tool for the job is a Dremel with a cut off wheel the smaller the better. Cut from the back side and put masking tape on the front side. Cutting stainless with any type of a toothed blade is a *****. Drill holes in the corners cut the line between the holes with the Dremel and finish with a corner file.

 

[Mike Folks]

Try; www.panelpunches.com or www.greenlee.com

 

[RTM]

Best tool for the job is a Dremel with a cut off wheel the smaller the better. Cut from the back side and put masking tape on the front side.

Cut thru the tape? Or next to it? In wood it's thru to avoid splintering, first I've heard of for metal, I do so little. Thanks

 

[dnschmidt]

I cut through the tape in this instance. Normally you use the tape as a cut guide in this case it prevents the sparks of the cutting wheel from defacing the stainless steel.

 

[RTM]

Thanks, will try it next time.

 

[toplessHO]

I cut through the tape in this instance. Normally you use the tape as a cut guide in this case it prevents the sparks of the cutting wheel from defacing the stainless steel.

spraying with PAM before cutting or welding will do that too.

 

[theoldwizard1]

AVE : How to Drill Square Holes!

 

[charlestmann]

As an alternative the Flameboss unit will accept the BBQ guru fan (same plug). It might be less trouble to purchase the fan and adapter plate. I did something similar for my Gateway drum and Flameboss 300. It's the lazy way out though!

 

[johninct]

I had to do a square hole in stainless washer to fix my toilet handles. I filed the hole square.

 

[Parrothead]

Dremel with fiber reinforced cutting discs. I love my 395. I can cut tile around a shower valve, or stainless steel with the right blades.

 

[radio2000]

Got it done
https://photos.app.goo.gl/toELzJVmt7gkheLs7

Drilled the four corners then used a cutting disc in the Dremel

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