Drill press for making chassis holes

Carlman · « **on:** 20 Apr 2004, 12:59 pm »

I need to make cutouts for a couple of things I'm making.
I'm building a small phono pre and putting my amp in a new case. I don't know the bit sizes for binding posts and jacks but, I feel that'll be pretty easy to find out.

However, what about things like the IEC inlet? How do you cut those? (and make it somewhat neat)

Also, does anyone have recommendations on bits to use on aluminum and steel? Also, what speed is best... Is Delta a good brand?

Thanks for any suggestions.

-Carl

mgalusha · « **Reply #1 on:** 20 Apr 2004, 01:20 pm »

Carl,

Many binding posts require 1/2" holes on 3/4" centers. RCA jacks vary, some are 7/16" but you should measure the ones you are planning on using.

I cut IEC openings by carefully laying it out, drilling a 1/4" hole in each corner and using a coping saw to cut the sides. Finish it off with a smooth file. Since the lip of the jack will cover the edges they don't have to be perfect. I have done several chassis using this method and the IEC's look like they were born there.

I cover the chassis with 2" masking tape before working on it. It makes laying out the hole locations easy and prevents scratches.

I suggest buying a set of high-speed bits covering from 1/64 to 1/2" by 64's (assuming you don't have some already). This will give you just about everything you need. I also suggest the use of a step drill. A common one is the "Unibit". These work great for sheet metal such as a chassis. Regular bits can tear thin metal.

The Delta tools are pretty good if you don't buy the bottom of the line. The $99 special at Lowes or other home centers is what I would call "fair". I have owned one and was disappointed as the chuck was really bad and some drills would run straight and others would wobble.

mike

JoshK · « **Reply #2 on:** 20 Apr 2004, 01:44 pm »

Mike pretty much laid it all out for you. Well said!

I have been playing around, mostly by trial and error and it is a lot of fun. Some of Mike's tips could have helped, had I known then. It certainly is fun to create things yourself.

I have a drill press from grizzly.com. 2nd or 3rd one up and think it is great. Really well made and solid, certainly better than most bottom of the lines at HD or Sears but about the same price.

Carlman · « **Reply #3 on:** 20 Apr 2004, 02:05 pm »

Thank you both.. It's one thing to conceptualize and another to hear from experience. Thanks for the tip on the Grizzly site...
They have THIS one that looks pretty cool.

-C

mgalusha · « **Reply #4 on:** 20 Apr 2004, 03:51 pm »

The drill press you linked to should do very nicely. I have been eyeing this one myself. I want the addtional height and the offset sanding hole/dust port.

JoshK · « **Reply #5 on:** 20 Apr 2004, 04:13 pm »

I think this one is the one I own but I wish I would have gotten the radial drill press. There has been a number of times where I could have used the extra depth.

Dan Banquer · « **Reply #6 on:** 20 Apr 2004, 05:56 pm »

I have been looking for punch that will do an IEC inlet but haven't found one. If anyone knows where I could find one I would be very appreciative. Doing it with the drills, nibbler, and file is a pain in the A__!!!!!

when I do a prototype.
d.b.

scottnixon · « **Reply #7 on:** 20 Apr 2004, 06:58 pm »

http://www.deltron-emcon.com/products_services/products.asp?id=2058&title=MANUAL%20HOLE%20CUTTING%20TOOLS%20-%20RECTANGULAR%20HOLE%20CUTTER&oldid=Products%7C0%23connectors%2C+die+cast+enclosures+and+production+tooling%0D%0A%7C1880%23production+tooling%7C2008%23manual+hole+cutting+tools%7C2055%23

You can custom order through Mouser. It takes months and these are expensive. Mine was over a hundred bucks, but to me worth it. You may be able to get these from a euro-supplier faster.

gonefishin · « **Reply #8 on:** 20 Apr 2004, 07:18 pm »

Hi guys,

Is there anything that not too expensive yet effective that you could recommend for a punch?

Also, are the little mill/lathe combo's worth it? The price doesn't seem too bad...I just can't afford a real mill or lathe...and would like to find out if the little ones I've seen are more than just toys.

thanks!
dan

Dan Banquer · « **Reply #9 on:** 20 Apr 2004, 07:30 pm »

Thanks for the link Scott.
d.b.

rosconey · « **Reply #10 on:** 20 Apr 2004, 07:39 pm »

gonefishin
they just opened up a harbor frieght down the street, ive looked at the little mill lathes- not that bad for the cash, wait till they have them on sale-
they have stuff almost half price all the time, ive saved alot of cash when stuff goes on sale.
they had a drill press the other day for 39$(79) that was well worth it.i picked up a air hose on a spring reel instead for 69$ - 119$
i'm waiting for the radial one to go on sale.[/list]