Square hole in control panel - how to do it?

cnlmoore

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I'm working on a project that requires a square hole cut into it for a roller. I've cut plenty of circles with a green lee punch set, but a square? Do punch sets exist or I'm I looking at using a dremel tool?

Any input appreciated.

EDIT: OK, found square hole punches but they are too small and way too expensive. Anyone cut a square hole in metal before?
 
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personally, this is how i'd to it.

first, mark out the square with a sharpie or whatever.
second, drill a hole in each corner so you don't go past the edges of the corner.
third, get a pneumatic die grinder with a cutting wheel and cut through the metal with that. use a file to clean it up after.
 
Nibbling cutters are great, but most control panels are too thick to use one on. :(

Another way to do it is to use a dremel with cut off wheels if you don't have a die grinder. It'll be SLOW but it'll work. Either way they'll both cut at a slight angle so you'll have to straighten the edges up with a file.

RJ
 
Depending on how big the hole is, if it were me, cut a round hole, and just use a metal file to square it up. A little bit of elbow grease involved but its not that bad in most cases.
 
Dremel is how I'd do it... but I can't think of any other tool that I have available that could do that.

DogP
 
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