Comments on: Making panel holes

By: acidblue

acidblue — Sat, 02 Jan 2010 20:01:55 +0000

I don’t know how I got along with out put a step drill.
Drilling is so much easier with one.

BTW I’ve always called it “chaff,” that metal goo you get .

By: Bern

Bern — Sun, 18 Jan 2009 03:21:00 +0000

In the past I've used brad-point (or lip & spur) drill bits for cutting holes in panels. They leave a tiny bit of swarf on the back face, but usually not much, and they normally make quite a clean hole.

Here's a wikipedia link to what I'm talking about. That article suggests they can only be used for soft metals - I've used them successfully on aluminium & plastic panels, haven't tried steel, though I guess you could use one to score the panel from both sides before using a conventional drill to cut through. A drill press is a definite must if you want any sort of accurate holes, though. Cutting aluminium with a hand-held drill makes it very difficult to get round holes...

By: Dunx

Dunx — Sat, 17 Jan 2009 17:23:00 +0000

I think the word you are looking for describing the metal goo that is on the exit side of the drill hole is “swarf”.

By: Anonymous

Anonymous — Thu, 15 Jan 2009 02:56:00 +0000

If you really want precission cut holes for various projects get a knock out punch. Tool manufacturers such as Greenlee sell basic kits and specialty dies.

By: Anonymous

Anonymous — Thu, 15 Jan 2009 00:47:00 +0000

I've made holes for 25 pin RS232 ports with a punch before. Granted… it's a specialty tool (especially now), but it does a great job. For rectangle holes try this link. http://www.mygreenlee.com/Products/main.shtml?greenlee_category_id=2&product_category=143&adodb_next_page=1

By: Aris

Aris — Wed, 14 Jan 2009 18:20:00 +0000

Indeed the step drill was of the worst quality available (I got the cheapest on ebay just to try it out). But now I’m on the hunt for a good one!

By: Anonymous

Anonymous — Wed, 14 Jan 2009 18:14:00 +0000

The first picture shows you need a better quality step drill and a drill press.
Second picture shows that you need much less pressure when tapering a hole.
Always let the drill do the cutting, you should not need to push the drill all that hard, if you do you need better drill bits or a faster drill.

By: Collin Mel

Collin Mel — Wed, 14 Jan 2009 17:32:00 +0000

likely depends on the particular nibbler one nibbles with – mine successfully chomped 2mm snacks tho

By: Phil

Phil — Wed, 14 Jan 2009 17:32:00 +0000

Of course Harbor Freight is the bomb when it comes to step drills:

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=96275

By: Aris

Aris — Fri, 09 Jan 2009 07:39:00 +0000

Does the nibbler work for thick sheets? (like 2mm eg)