Cutting Metal

[KronoLeginaire]

Well, i want to do a window mod on my new Neon Light case but I cannot get a Dremel at this particular time. I tried Tin snips but I need a hole in order to start and I don't know how to goabout making a goodsized one. Dose anyone know any other ways that I may go about cutting my case panel?


Thanks!

[bailey]

take the cover to a electrical shop and they would be happy to knockout a hole of any size you want for nothing.

[highrisemech]

A drill with the proper bits will replace a dremmel.

[KronoLeginaire]

What do you mean by an electrical shop? An actual office of an electrician?

[Gabe]

Have you thought about using a jigsaw?

[KronoLeginaire]

No cash to buy any power tools at this time. I know it sounds stupid but thats the way it is.

[highrisemech]

Without tools it is kind of rough but it can be done. Trace out what you want to cut. Lay the panel on a firm piece of wood surface, using a good flat screwdriver and a hammer stamp out your image then file and sand the edges smooth. Otherwise a good acetylene torch does wonders.

[KronoLeginaire]

I think i'll just make a layout on the back of the panel and take it somewhere to be cut, better that then risk messing up a panel to such a great case.

[highrisemech]

Definitly a good idea. I'm sure there are some good machine shops in your area. You can get an excellent job done in one of those. Check your yellow pages.

[bailey]

a electrician
or you could stop by my house and I will do it for you.

[jamesrpm]

Auto body shops have very nice plasma cutters just for cutting sheet metal. I'm sure if you asked they do it for you.
I'm a electrician and all my tools are for round holes , if that is what you want just stop by.

[KronoLeginaire]

Originally posted by bailey a electrician or you could stop by my house and I will do it for you.

Thanks for the offers to stop by ur houses guys, but I think I'll stay here. I may call Hopkins and Kipp and see if they can do it, they are a reputable name in our state but last time I called the guy who answered could have been a bit more friendly.

[Confused]

Sounds like you are talking about a big company and the guy answering the phone doesn't have time for a small job like that. Get to know someone with the tools (simple tools can do the job), like a neighboor, or a friend of a friend. If you have a jig saw, blades can be had for about $2.00 and they have hack saws with straight blades that sell for about $10.00 to $15.00. With those two options you could do it yourself.
Chas

[wedor]

Both the Acetylene torch and the plasma cutter would leave fairly jagged edges and a tinsnips would tend to warp the edges so none of these are particularly good options. As a side note, few autobody shops use plasma cutters as they tend to cause more trouble than they are worth.

[doctorgonzo]

I agree, find some small metal-working shop instead of a large business. They would probably be more inclined to help out. I would suggest a place I know of but, well, you are in Ohio and I am not!

[BFD Deadeye]

I have and have used my plasma cutter for years. Indespensible. I have never heard of them causing trouble for autobody work. I can cut a hole in a soda can just as smooth as the drink hole, then turn around and slice a 1/4" chunk of strap without touching any settings. I would think an autobody shop is the way to go. Heck, I've seen hole saws for $10 bucks that would cut a perfect hole for a 120-80 mm fan. It just pays to drill at high RPM with very little pressure...takes a few minutes, but will cut a beautiful hole, with VERY LITTLE filing needed afterwards.

[wedor]

I worked in a shop a good portion of my life, the plasma cutters available to us left slag around the hole. Plasma cutters also cut all the way through, most autobody panel removal calls for only the first of 2 surfaces be cut through. We played with plasma cutters for a time but ultimately found their use to too limited and the side effects like metal spray and slag to be more trouble than they were worth. There were and are much easier methods of panel cutting and removal.

[KronoLeginaire]

I called a place that is in the business of cutting metal but use a plasma cutter and said that my paint would get burned. Oh well... I buess I just won't do it.

BTW, I noticed when I tested my TinSnips out on anthor old case that after I cut metal the paint started chipping away from the area which had been cut. So even if I do find a way to cut this case, the paint may start pealing away anyway.

[HAL9000]

The autobody shops may have a sheet nibbler that would cut out that hole smooth and clean. You need a hole drilled to begin though.

[wedor]

Well if they are willing to cut the hole they may be just as willing to drill it before hand. Another little note, we quit using the nibblers because of the little sharp chips they left everywhere. Gee, I seem to complain about everything today. I ended up using an air powered mini saber saw for most things, nice clean cut, little or no edge distortion.

[KronoLeginaire]

Ok, I'm going to re-check prices on a Dremel but what tools do you guys reccomend, but stil I am worried about the paint chipping away afterwards.

[Confused]

You can get a small jig saw with a metal blade for far less than a dremel. Cut faster too. I own both and while dremel has it's uses, I'll take something bigger when it comes to cutting holes in metal as heavy as cases. If all I wanted was a hole I would use a hack saw before I would spend what a dremel cost. Of course you have to have a starter hole drilled in order to use the saws.
Chas

[KronoLeginaire]

Yeah, thats one problem I had when trying to use my tin snips. No starter hole and my currecnt wood bits can't go through.

[highrisemech]

I agree that a good hole saw on a drill will make a good hole in the metal. I use hole saws to drill into pipe, makes a perfect hole everytime.

[Confused]

Well if you have a drill (wood bits), pick up a fairly large metal bit, a straight hack or a jig saw with metal blade and go at it.
Chas

[Bad Coffee]

If you need to make a starter hole, start in the center of your proposed opening, and pound one through with a screw driver. Or, if you have a Rip hammer, (like a normal hammer but the back end that you use to pull out nails is straigt, not curved) just take a big swing! I would put the case on the grass, then hit it from the inside. You won't warp the case that way. Low tech!

to keep your paint from chipping, get some 1" masking tape, and tape where you want the final hole. Make sure the line that you will be cutting is in the center of the tape. or cover the whole side in contact paper, and draw your opening right on the contact. also, this will keep your case from getting scratched by the plate of the jigsaw when you make the cut.

BC

[wedor]

Originally posted by Bad Coffee You won't warp the case that way. BC

That is incorrect, you would probably get some bad warpage from that method, having played with sheet metal for a number of years I find it fairly sensitive to being beat on. Try it first on something that doesn't matter.

[highrisemech]

If your going to stamp out metal it has to be laid on a firm surface not grass.

[KronoLeginaire]

I'm not goign to beat the metal, I'm going to use a dremel or similar. I made the cut lines on the back side of the case though, do you think cutting from the back will be ok?

[Jenni]

Cutting from the back is fine