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 Post subject: Chassis work source?
PostPosted: Nov Sat 11, 2017 4:37 am 
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Joined: Jan Thu 01, 1970 1:00 am
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Location: Cambridge MN USA
Have an amplifier project I've been meaning to build for years, but doing the chassis work has been the biggest hold up. I've got all the punches for the tube sockets but need someone to do the almost 3" holes for the output transformers (CVP1s). Anyone know of somewhere I can get this done? I'd mark the centers for the holes before sending it out.

Thanks,

Scott


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 Post subject: Re: Chassis work source?
PostPosted: Nov Sat 11, 2017 5:21 am 
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Joined: Jan Thu 01, 1970 1:00 am
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Location: Massachusetts
You could buy a carbide hole saw to cut those holes

https://drillsandcutters.com/3-carbide- ... gKV_fD_BwE


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 Post subject: Re: Chassis work source?
PostPosted: Nov Tue 14, 2017 2:54 am 
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Wonder if it makes a cleaner hole than a conventional type? Rather expensive little bugger.

Scott


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 Post subject: Re: Chassis work source?
PostPosted: Nov Tue 14, 2017 3:00 am 
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Location: S. Dartmouth MA 02748-1225 USA
A good hole saw would work, cleanup the hole with a machinists edge breaker.


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 Post subject: Re: Chassis work source?
PostPosted: Nov Fri 17, 2017 6:06 am 
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N0BST wrote:
Have an amplifier project I've been meaning to build for years, but doing the chassis work has been the biggest hold up. I've got all the punches for the tube sockets but need someone to do the almost 3" holes for the output transformers (CVP1s). Anyone know of somewhere I can get this done? I'd mark the centers for the holes before sending it out.

Thanks,

Scott



Sure, I use a hole saw for all round holes. The large ones are 3". Pilot with a 1/4 inch drill. Then put the proper size hole saw on the chassis. Tilt the saw just a little to cut better. Hang on for dear life.
Attachment:
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 Post subject: Re: Chassis work source?
PostPosted: Dec Sun 10, 2017 5:45 am 
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Location: sunnyvale Ca.
For large hole like that I have made a layout and gang drilled them. Then some work with a Dremel tool to clean them up. You can see how they turned out in this thread.
http://www.antiqueradios.com/forums/viewtopic.php?f=8&t=205467
Part way down page two you can see the rough holes. Then further down is a pic of how they came out.
Mel W.


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 Post subject: Re: Chassis work source?
PostPosted: Jan Tue 02, 2018 9:24 am 
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Just about any decent quality hole saw will work but should be run at low speeds. Several years ago I purchased a bench-top Ryobi drill press on sale, having become increasingly tired of having to cut holes for analog panel meters in the front panels of re-purposed rack mount chassis with a saber saw and files.

The drill press has been a great asset in the shop and has enabled me to do things I would not attempt with a hand held drill motor. But the press turned out to be unusable for metal cutting with hole saws since the lowest RPM available at the chuck is way too high. My first attempt at this generated a lot of heat and very short life for the saws. Then I realized I would need much lower RPM. I'm still looking for a suitable permanent magnet DC motor but finding one that fits all the electrical and mechanical req's is daunting, and would in any case likely cost more than the $70 drill press did.

Back to using the big, heavy, powerful low RPM Milwaulke D-Handle 1/2" hand-held, requiring a lot of real-time finesse and patience. One false move, and... well, you know.

Long story short, it's the need for [low] speed in this case. - C-N-E -

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 Post subject: Re: Chassis work source?
PostPosted: Jan Tue 02, 2018 2:49 pm 
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Joined: Aug Tue 18, 2009 1:46 pm
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Location: Berlin, MA
I use an adjustable fly cutter like this one from home depot.
https://www.homedepot.com/p/General-Too ... gJ4QPD_BwE


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 Post subject: Re: Chassis work source?
PostPosted: Jan Tue 02, 2018 5:30 pm 
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Joined: Dec Fri 08, 2017 5:40 pm
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Location: 44141
I'm with Arnie. Use with a drill press; take your time and it works fine.

Bruce Hagen

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 Post subject: Re: Chassis work source?
PostPosted: Jan Tue 02, 2018 7:10 pm 
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Location: Los Angeles
Got to disagree with you guys, respectably of course.
I have found that a slight angle makes a good cut. That's after the 1/4" pilot hole is made.
Drill press is not good. Any speed will just eat the teeth and cause heat.
Clamp the job securely to the bench, or in a vise.
Use a drill motor on high gear, not low. If the drill gets stuck, the motor will not stall in low gear.
Could cause injury. I use a Dewalt 20volt cordless.
Keep the motor turning all the way through.
Check a few posts up to see my work.
Happy drilling.

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 Post subject: Re: Chassis work source?
PostPosted: Jan Wed 03, 2018 1:08 am 
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N0BST wrote:
Wonder if it makes a cleaner hole than a conventional type? Rather expensive little bugger.

Scott


you're looking in the wrong place. $14.52 w/free shipping (prime)
https://www.amazon.com/dp/B00005LEZK/re ... B002FYFYW8

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 Post subject: Re: Chassis work source?
PostPosted: Jan Wed 03, 2018 3:20 am 
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Location: Los Angeles
glue_ru wrote:
N0BST wrote:
Wonder if it makes a cleaner hole than a conventional type? Rather expensive little bugger.

Scott


you're looking in the wrong place. $14.52 w/free shipping (prime)
https://www.amazon.com/dp/B00005LEZK/re ... B002FYFYW8



That's exactly what you need. Don't forget the spindle.

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 Post subject: Re: Chassis work source?
PostPosted: Jan Wed 03, 2018 3:24 am 
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Arnie-AE wrote:
I use an adjustable fly cutter like this one from home depot.
https://www.homedepot.com/p/General-Too ... gJ4QPD_BwE




For metal?

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 Post subject: Re: Chassis work source?
PostPosted: Jan Wed 03, 2018 11:47 am 
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Joined: Aug Tue 18, 2009 1:46 pm
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Location: Berlin, MA
Yes - I have been using a fly cutter for chassis hole cutting for decades, the same cutter. I've cut through 1/8 inch aluminum panels for meter holes, etc. If the cutter edge gets a bit dull, just dress it up with the bench grinder, just like a lathe cutting tool, which is what it is. I do use my floor standing drill press and usually mount the work to the table so it diesn't move around. I've never been dissatisfied with the results.


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 Post subject: Re: Chassis work source?
PostPosted: Jan Wed 03, 2018 6:31 pm 
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Location: Los Angeles
Arnie-AE wrote:
Yes - I have been using a fly cutter for chassis hole cutting for decades, the same cutter. I've cut through 1/8 inch aluminum panels for meter holes, etc. If the cutter edge gets a bit dull, just dress it up with the bench grinder, just like a lathe cutting tool, which is what it is. I do use my floor standing drill press and usually mount the work to the table so it diesn't move around. I've never been dissatisfied with the results.



I like it. For that you would need the drill press. Does it work best at lower speed?
I need one of those.

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 Post subject: Re: Chassis work source?
PostPosted: Jan Wed 03, 2018 7:53 pm 
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john8750 wrote:
Arnie-AE wrote:
I use an adjustable fly cutter like this one from home depot.
https://www.homedepot.com/p/General-Too ... gJ4QPD_BwE




For metal?


Clamps, gloves, googles and a prayer.

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 Post subject: Re: Chassis work source?
PostPosted: Jan Thu 04, 2018 11:55 am 
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Location: Berlin, MA
Quote:
Clamps, gloves, goggles and a prayer.


Oh yes! If you don't take good care, using a fly cutter can be dangerous. And, I'm not saying it's the best solution - chassis punches in my opinion would be the best - I'm just saying that's what I use for large round holes. For flat plates, like the panel I'm currently working on, I screw the panel to a piece of wood and then clamp the wood to the drill press table. I operate the drill press at a medium speed. Hole saws may be better also, but I never seem to have the right size. Since the fly cutter is adjustable, I don't have to go buy a new tool to cut a hole. I'm sure it's not the right tool for everyone.


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