Making Square Holes In Sheet Metal

Use this technique to make perfect square or rectangular holes in 040 aluminum.

Making square holes in sheet metal.

Use a hydraulic press to gradually and smoothly increase pressure until the broach is forced through the hole cutting material and forming a square. This will create dimples in the sheet. Use either a fine tipped sharpie or a metal scriber depending on your tolerances. Drag an awl along the end of the combination square blade.

Use your center punch to strike at the center of the hole. The multi positional guides are 1 aluminum angles held in position with clamps i use both c clamps and cleco s. The first step for all these methods is to mark where on the sheet you want your square hole and sometimes the center of the square. Drilling a hole in sheet metal with a twist drill is a rather straightforward operation.

Super easy tip in this video we show you how to drill a hole for a carriage bolt. Simple tool to drill square holes. Drill a hole in the metal close to but smaller than the finished hole size. Move the combination square and repeat the process to mark a straight line on each side of the drilled hole forming a square.

This is a simple diy solution to broaching odd shaped holes in metal. Next use a compass to outline the edge of the hole. The bit used is a 1 8 single flute type. At first locate the center of the whole.

Put your ink to the use and mark the hole center. Set the base of a combination square on one side of the material. Now it s time to use that center punch. Here are some methods depending on the tools you have and the size of the square hole and the thickness of the sheet metal.

Blacksmithing for beginners cutting a square hole in sheet metal. Drill a hole large enough for a jigsaw blade in the part you re cutting out then cut it out with the jigsaw you ll have to curve into the straight lines of your square hole and do a little whittling but it works level 1. How to use chisels instead of files to cut a share hole for carriage bolts. Insert the broach and ensure it lines up at 90 degrees from the work peice or the hole will be crooked.

The router is just a standard off the shelf ryobi router mounted under a home made router table.