I use a quality bi-metal hole saw, not some Harbor Freight junk, for meter
holes.
Even so, nothing lasts forever and many just cant seem to throw a worn out
tool away.
Carl
KM1H
----- Original Message -----
From: "Manfred Mornhinweg" <manfred@ludens.cl>
To: <amps@contesting.com>
Sent: Friday, September 13, 2013 1:37 PM
Subject: Re: [Amps] Workshop Danger
Like many homebrewers, I cut my panel holes with a jigsaw, and finish them
with files. The advantage: Essentially any shape and size is possible.
Disadvantage: It takes a bit of practice to get nice, clean, good-looking
results.
It's a good idea to use panels of a reasonable thickness. There is just no
point in making them as thick as an armor plate! For small boxes I use 1mm
aluminium sheet, for bigger ones slightly thicker sheet, and only for the
biggest boxes holding the heaviest sort of components I use 3mm thick
aluminium.
On the other hand, I have used the jigsaw+file method even in 8mm thick
steel, when building machinery! That takes some patience, though, and
might wear out one jigsaw blade per hole. But that's still cheaper than
having the work done by others.
Shop safety is not to be taken lightly. It pays to think in advance what
can go wrong, and prepare for it. For example, a jigsaw blade can shatter
and fly away, and small metal chips will certainly fly around. So, eye
protection is a good idea. I also use ear defenders, as I like listening
to music and don't want to go deaf. And un-deburred metal edges can cut
fingers... but that's pretty obvious! Come on, we are no kindergarten
anymore! ;-)
Manfred
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Visit my hobby homepage!
http://ludens.cl
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