KNOCK OUT 4

[72mattski]

I need to make several, ten to be exact, 2.15" x 3" rectangular holes in a new control panel door, about 16 gauge thick. This is to mount some Red Lion, Cub5 counter/rate meters. Is there an inexpensive way to do this with out completely disassembling the panel door or buying a die and punch set (for this size the price from Greenlee is around $1k, not counting the manual hydraulic pump required). I could use a jigsaw with a metal blade, but I fear the cutting will be less than perfect. Any ideas?

Thanks in advance.

Matt
Chief Engineer

 

[DRWeig]

Is there not a local machine shop that can do that for you inexpensively?

Best to you,

Goober Dave

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[Compositepro]

The cut does not need to be perfect. The bezel of the instrument covers up the cut edges. A step drill is the best way to make a starter hole in sheet metal for the saw blade. Masking tape can protect the paint while sawing.

 

[bigTomHanks]

Layout areas. Drill out corners and then use the jig saw with a metal cutting blade to cut out the straight runs.

 

[MikeHalloran]

If the panel door is aluminum, you can use a hand nibbler.
If it's steel, you need a bigger hand.

The real trick to a neat job is to cover everything with blue tape before you start, and work carefully. Or pay someone who works carefully to do it.


Mike Halloran
Pembroke Pines, FL, USA

 

[AWloo]

McMaster Carr, has hand nibblers that can cut up to 1/4" steel and their smaller sizes are rated at a maximum of 16 Gauge. But a simple technique would be for a jig saw like the others have suggested above.

 

[72mattski]

As always, great feedback. I love this website. My original suspicions confirmed, I think I will go the way of the jig saw.

Thanks to all you guys.

Matt Merrick
Chief Engineer

 

[SceneryDriver]

If you can un-mount the door, laser cutting or water jet cutting can be a viable and cost effective solution.

A jig saw will certainly work; use a fine tooth blade, and work slowly and carefully. Cover everything around the holes with blue painter's tape. The tape will prevent the vibrating saw from embedding metal chips in the cabinet's paint. Burnish/press the tape down well, or the blade and saw base will peel up the tape as you cut.


SceneryDriver

 

[dvd]

 

[bin95]

Next time (and anyone else seeing their design requires 5-10 counter/rate meters in a single panel door), use a HMI screen instead like Allen Bradley's Panelview. Then you will be only cutting out one squire to mount HMI screen, and you get the added functionality and expandability at little cost.