Best way to cut metal?

[Mo0o]

I'm trying to cut a hole into the side of my shuttle case and I was wondering what the best technique was. I dont have any large power tools, just drills, dremel and thats about it. Could I draw an outline, make alot of holes along the line then use the dremel? And also what is the best technique to file down the rough edges without damaging the main surface?

 

[bmacd]

plasma cutter all the way!!! Just use a dremel.

-=bmacd=-

 

[Mo0o]

Originally posted by: bmacd
plasma cutter all the way!!! Just use a dremel.

-=bmacd=-

So just take a dremel w/ the spinning wheel and start cutting? isn't there more of a risk of me messing up this way, like if i slip a little and make a huge nasty cut on the surface.

 

[Isshinryu]

Originally posted by: bmacd
plasma cutter all the way!!! Just use a dremel.

-=bmacd=-

I use a plasma cutter day in and day out...fun little toy. It'll cut through 3/4" of carbon steel without a second thought.

 

[bmacd]

Originally posted by: Mo0o

Originally posted by: bmacd
plasma cutter all the way!!! Just use a dremel.

-=bmacd=-

So just take a dremel w/ the spinning wheel and start cutting? isn't there more of a risk of me messing up this way, like if i slip a little and make a huge nasty cut on the surface.

if you mar the surface, there's no fixing it. A dremel (or any rotary tool) is going to be the easiest thing for you. Might want to take a look at the RotoZip.

-=bmacd=-

 

[Isshinryu]

Originally posted by: Mo0o

Originally posted by: bmacd
plasma cutter all the way!!! Just use a dremel.

-=bmacd=-

So just take a dremel w/ the spinning wheel and start cutting? isn't there more of a risk of me messing up this way, like if i slip a little and make a huge nasty cut on the surface.

Just go slow, I've done plenty of cuts to my computer case with a dremel with no problem.

 

[notfred]

Seen that water jet cutter thing they have on american chopper?

 

[TitanDiddly]

If it's a fan, get a holesaw. If not, use a Dremel, and mask off what you don't want to cut. A jigsaw may work also.

 

[Mo0o]

Originally posted by: bmacd

Originally posted by: Mo0o

Originally posted by: bmacd
plasma cutter all the way!!! Just use a dremel.

-=bmacd=-

So just take a dremel w/ the spinning wheel and start cutting? isn't there more of a risk of me messing up this way, like if i slip a little and make a huge nasty cut on the surface.

if you mar the surface, there's no fixing it. A dremel (or any rotary tool) is going to be the easiest thing for you. Might want to take a look at the RotoZip.

-=bmacd=-

Hmm, what if i made a bunch of holes along the lines. Then use the dremel to "connect the dots"

 

[ThisIsMatt]

Hole saw or jig saw.

 

[Bryophyte]

Fire. It's very satisfying to cut metal with fire. Satisfies the primitive part of your personality.

Or you could use your dremmel with an abrasive bit made for metal and avoid melting your case into a lump.

 

[Mo0o]

Originally posted by: Isshinryu

Originally posted by: Mo0o

Originally posted by: bmacd
plasma cutter all the way!!! Just use a dremel.

-=bmacd=-

So just take a dremel w/ the spinning wheel and start cutting? isn't there more of a risk of me messing up this way, like if i slip a little and make a huge nasty cut on the surface.

Just go slow, I've done plenty of cuts to my computer case with a dremel with no problem.

hmm ok

 

[Shawn]

jigsaw

 

[bmacd]

Originally posted by: ThisIsMatt
Hole saw or jig saw.

If somebody has to ask how to cut a hole in their case, i'm willing to bet a jig saw would be a little overwhelming, not to mention an overkill purchase for a small project.

-=bmacd=-

 

[GRIFFIN1]

nibbling tool.

Radio Shack

Kronus? Nibbling Tool

$12.99 Brand: Kronus?
Catalog #: 64-2960

This isn't a fast way to make a hole in metal, but it will give you good results.

 

[ThisIsMatt]

Originally posted by: bmacd

Originally posted by: ThisIsMatt
Hole saw or jig saw.

If somebody has to ask how to cut a hole in their case, i'm willing to bet a jig saw would be a little overwhelming, not to mention an overkill purchase for a small project.

-=bmacd=-

What would you rather have me say? Use a dremel and eff the whole thing?

 

[Chu]

Originally posted by: Mo0o

Originally posted by: bmacd
plasma cutter all the way!!! Just use a dremel.

-=bmacd=-

So just take a dremel w/ the spinning wheel and start cutting? isn't there more of a risk of me messing up this way, like if i slip a little and make a huge nasty cut on the surface.

NO! Here is what you want to do:

1. Outline the hole with something erasable (GREASE pencil works great).

2. Use the dremel spinning wheel to cut out as much as you can. Don't try to cut out the circle - your going for more a n-gon shape where the verticies are NEAR but not ON your circle.

3. Use the spinning sander to do the rest. Takes some time -- but you'll get the circle dead on.

-Chu

 

[kami333]

Hole saw then a dremel to unsharpen the edges. You could just use the dremel but I find that the hole doesn't come out as completely round.