Best way to cut a hole in a metal case?

[bullion416]

I am planning on buying a window thing for my case, but need advice on how to accurately cut a hole in the metal case. What have you guys done and what did you use?

 

[FlowerMan]

For a big hole like that, I imagine a jigsaw would be the easiest. Hole saws are out of the question, they're just for cutting holes for blowholes. Either a jigsaw or a Dremel, but you're gonna be spending a heck of a long time cutting and replacing wheels with the dremel. You gotta finish up with a dremel anyways, so you'll be using it regardless

 

[SnowPunk98]

Dremel only way to go

 

[Mitzi]

Yup, I'd say a Dremel too - you can cut a much neater hole than with a jigsaw. Get the heavy-duty cutting discs and get plenty of 'em!

 

[Dan]

For a window I used a jigsaw. Trace out your pattern, cover it with a double layer of masking tape and use a metal cutting blade. (And be sure to wear safety glasses!) For smaller holes, e.g., 80mm and 92mm blowholes, I use bi-metal hole saws attached to my drill.

 

[TakeFlight]

As far as I'm concerned the easiest way is to use a jigsaw. IMO, it will give you the cleanest, straightest cut since it practically guides itself. As opposed to the Dremel which you need to have a really steady hand to keep straight.

 

[AkumaBao]

Does anyone use saber saws anymore?

 

[chizow]

I used a combination of a jigsaw and a holesaw for my blowholes. My dad had all the tools so that made it easy. I just drilled about 10 pilot holes with the holesaw (2 80mm blowholes) and used the jigsaw to play connect the dots.

Chiz

 

[FlowerMan]

If you use any type of saw, make sure you have cutting oil. saves you time and saves your saw. Makes clean up a heck of a lot harder, but its worth it.

 

[Jen]

I have used grinders to dremals to jigsaws to hacksaws............and a hand nibbler which is nice as well


Jen

 

[dew042]

<< Dremel only way to go >>



personally i prefer the shotgun reduction method best



dew.

 

[JCobra14]

I'm working on this same project, and i'm wondering what's the best dremel tool to clean up with, once you've cut the hole with the cutting disc?

 

[TimberWolf]

Do a search for item 28012 - "Mini Nibbler" An automotive sheetmetal nibbler beats a jigsaw for window projects. Wear gloves to avoid blisters. Leaves minimal burrs that you can finish with a medium-tooth file.

Just did a window yesterday - the cut-out took me less than 1/2 hour from layout to deburring. I've done over a dozen windows and 5" blowholes, along with other assorted projects - well worth the investment.

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Edit: Fixed link

 

[Mitzi]

<< personally i prefer the shotgun reduction method best
dew. >>



I guess it saves having to drill pilot holes!

 

[dew042]

<<

<< personally i prefer the shotgun reduction method best
dew. >>



I guess it saves having to drill pilot holes! >>



don't be silly. pilot holes are still a must! neatness is absolutly imperitive!



dew.

 

[GoldenTiger]

Go for a jigsaw, and then a dremmel to finish up the edges and corners .

 

[FlowerMan]

I think the tool you should use really depends on the application. Are you cutting through thin cheapo steel or the thick, tough stuff? Soft aluminum (annodized, but still relatively soft)?

 

[ChrisADuffy]

Dremel!

 

[jere01]

Go Here

They've got instructions for cutting holes with a dremel.