Square hole for ARB type switch.

[toyrunner95]

So I have been contemplating this for awhile. The ARB type rocker switch takes a square hole. I can cut them in plastic and I can cut them in wood... but what about metal? I tried making a template and drilling out the corners then cutting between the holes. Well.. the only tool I have to do this is a jigsaw with a metal blade. This is really really annoying. Not only do I hate jig saws becase they are super loud and rattle your bones, but they kick and buck and are dangerous.

So I thought about a die grinder with a tiny cut off wheel, but I can't find a small enough cut off wheel. Then I tried a cut off wheel tool, but my compressor cant keep up with it.

Is there a better faster and easier way to do this?

I am using a center console out of a cop car like expedition xterra did. i think it will work great. but i am going to be cutting more than one hole and a couple are diferent sizes.

HELP!

 

[IH8RDS]

LOL I feel you're pain. I ended up using a high speed disk cutter and cutting the squares out. The marks left behind in the corners I just filled in with the welder and grinded back down. Big pain.

 

[absolute]

Why not a Dremel??

 

[theksmith]

i'll second the dremel, they have several different sizes of cutoff wheels for metal and other materials

with regards to the jigsaw, for precision cuts, make sure the little switch that sets the way the blade can move forward as well as up and down is in the position that does not move it forward at all (i have no idea what this setting is called).

 

[lowenbrau]

Sounds like a job for a nibbler...
the klein -
http://www.acetoolonline.com/Klein-76011B-Nibbler-Cutting-Tool-p/kle-76011b.htm

the others-
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=97636
http://www.radioshack.com/product/index.jsp?productId=2289712

 

[Sportsman Matt]

I usually drill the 4 corner holes, use a jig saw blade and a clamping key hole saw handle used for sawzall blades. Then just use a square file to finish up the edges and corners. Just remember if you go too fast, you're likely to make it too long or too wide or not square. Just take your time and it will turn out perfect.

 

[Ireland]

i'll second the dremel, they have several different sizes of cutoff wheels for metal and other materials

with regards to the jigsaw, for precision cuts, make sure the little switch that sets the way the blade can move forward as well as up and down is in the position that does not move it forward at all (i have no idea what this setting is called).

That action is called the orbital action on Jigsaws and is not recommended for cutting thin metal.
I think the dremel is the right tool for this fine a job, just remember to be careful of the sparks flying inside the dash...

 

[ntsqd]

The problem with a sabre saw on sheet-metal is it usually violates the 3 teeth rule. Without 3 teeth always engaged in the work you're killing the blade, getting poor cut results (without exceptional operator control), and it makes a lot of noise.

The nibbler mentioned by lowenbrau, if the metal is within it cutting range for that type of metal, is the cleanest way to go. I've been known to use a Greenlee panel broach to successively rough out the opening and then finish it off with a hand nibbler.

 

[toyrunner95]

well the metal is 3/16 sheet. and its not in a dash, its going to be a plate on the console so its not in the truck.

I thougt about my dremel, but where do i get a cut off wheel that will A. fit the dremel, and B. not explode. every blade i have tried has left chunks embedded in my celing and walls.

 

[cruiseroutfit]

Plasma cutter, clean up with a carbide tool on a die grinder. If its in a dash or painted surfaces, I'de use the 4 corner drill bit method and a small die grinder wheel.

 

[bucketosudz]

For what its worth, you can get mesh re-inforced cutoff wheels for the Dremels. I have also doubled up the thinner ones and run them at a lower RPM. It isnt the safest but with finesse and patience it can be quite effective. We used many of these discs in Dental Lab school to seperate castings, and a bit of flex and POOF you have disc pieces everywhere!! I know of what you speak. You might also consider some stones also. Just a couple of thoughts.

 

[ntsqd]

If 3/16" then a 16 TPI blade is the coarsest and an 18 or more would be better. Those nibblers aren't going to work.

I've done the doubled-up Dremel discs too. Worked great for putting a CVJ retainer ring groove in a shortened SAW half-shaft. For this I don't that it would be the hot set-up. Worth trying if nothing else it getting it done.

In the old days I'd drill the corners and then drill enough over-lapping holes to get a hacksaw blade through the work piece.

 

[Harald Hansen]

What about a square hole punch?

The linked one is rather pricey, though...

 

[ExpoMike]

well the metal is 3/16 sheet. and its not in a dash, its going to be a plate on the console so its not in the truck.

I thougt about my dremel, but where do i get a cut off wheel that will A. fit the dremel, and B. not explode. every blade i have tried has left chunks embedded in my celing and walls.

Holy crap, 3/16" plate to hold a switch. And I thought I way overbuilt things... :ylsmoke: At that thickness, I would break out my plasma cutter and a straight edge. I would drill the corners first, then use a square file after the straight cuts were done, to square up the corners.

 

[granitex1]

A dremel with the fiber cut off wheels will be just fine, the 90 deg attachment will make it much more comfortable to do the work. I have cut leaf springs in half with one without breaking disk, so you can do do 3/16th steel. The trick is to let the speed of the tool do the work.