Hacking a Plastic & Metal Sandwich...

[Guest]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

Hello people:

I would like your knowledgeable opinion regarding the practice of
cutting holes through things other than wood. In my case, I am
wanting to cut two accurate holes (measuring 80mm in dia; 3 1/8")
through a panel of thin sheet metal attached to high impact plastic,
like the type used in making cabinets for electronics and PCs.
Actually, I've given in to the idea of trying to get around *not*
improving the airflow in an old Sony Vaio case for overclocking and
will bite the bullet on this one (see thread:
http://www.google.ca/groups?q=insubject:Sony+author:Bruce+author:Gillis&hl=en&lr=&selm=2c942c97.0502041219.ff6042%40posting.google.com&rnum=1)

After looking carefully at the piece, I believe that I will get better
results with the holes if I leave the two materials together for the
cut rather than doing each seperately. However, I don't know squat
about hole saws. What grade of hole saw is best for this job? or if
a hole saw is even recommended for this job?

Thanks,

Bruce

 

[Chris]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

"Bruce Gillis" <brucekg78@yahoo.com> wrote in message
news:2c942c97.0502221310.4e00c062@posting.google.com...
> Hello people:
>
> I would like your knowledgeable opinion regarding the practice of
> cutting holes through things other than wood. In my case, I am
> wanting to cut two accurate holes (measuring 80mm in dia; 3 1/8")
> through a panel of thin sheet metal attached to high impact plastic,
> like the type used in making cabinets for electronics and PCs.
> Actually, I've given in to the idea of trying to get around *not*
> improving the airflow in an old Sony Vaio case for overclocking and
> will bite the bullet on this one (see thread:
> http://www.google.ca/groups?q=insubject:Sony+author:Bruce+author:Gillis&hl=en&lr=&selm=2c942c97.0502041219.ff6042%40posting.google.com&rnum=1)
>
> After looking carefully at the piece, I believe that I will get better
> results with the holes if I leave the two materials together for the
> cut rather than doing each seperately. However, I don't know squat
> about hole saws. What grade of hole saw is best for this job? or if
> a hole saw is even recommended for this job?
>
> Thanks,
>
> Bruce


use a hand punch tool easier neater and no mess.
http://rswww.com/cgi-bin/bv/browse/Module.jsp?BV_SessionID=@@@@0251423680.1109108387@@@@&BV_EngineID=ccceadddlkmgllmcfngcfkmdgkldfhg.0&cacheID=ukie&3286561514=3286561514&stockNo=548423
Circular (Imperial) Hole Cutter



--
Chris
Technical director CKCCOMPUSCRIPT
Apple Computers, Intel, Roland audio, ATI, Microsoft, Sun Solaris, Cisco and
Silicone Graphics.
Wholesale distributor and specialist audio visual computers and servers
FREE SUPPORT @,
http://www.ckccomp.plus.com/site/page.HTM
ckccomp25@hotmail.com

 

[Guest]

Archived from groups: alt.comp.hardware.overclocking (More info?)

On 22 Feb 2005 13:10:03 -0800, brucekg78@yahoo.com (Bruce Gillis)
wrote:

>Hello people:

>I would like your knowledgeable opinion regarding the practice of
>cutting holes through things other than wood. In my case, I am
>wanting to cut two accurate holes (measuring 80mm in dia; 3 1/8")
>through a panel of thin sheet metal attached to high impact plastic,
>like the type used in making cabinets for electronics and PCs.
>Actually, I've given in to the idea of trying to get around *not*
>improving the airflow in an old Sony Vaio case for overclocking and
>will bite the bullet on this one (see thread:
>http://www.google.ca/groups?q=insubject:Sony+author:Bruce+author:Gillis&hl=en&lr=&selm=2c942c97.0502041219.ff6042%40posting.google.com&rnum=1)

>After looking carefully at the piece, I believe that I will get better
>results with the holes if I leave the two materials together for the
>cut rather than doing each seperately. However, I don't know squat
>about hole saws. What grade of hole saw is best for this job? or if
>a hole saw is even recommended for this job?

>Thanks,

>Bruce
http://www.over-clock.co.uk/articles.php?action=show&showarticle=5

 

[Guest]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

What a coincidence, I just asked this question last week in uk.d-i-y.
http://groups-beta.google.com/group/uk.d-i-y/msg/d4473816b4b5d2f3
Well ok, a 120mm hole and just in the steel case.
Anyway, the diy guys came up with about a dozen different ways and
it caused a little controversy there.
David


"Bruce Gillis" <brucekg78@yahoo.com> wrote in message news:2c942c97.0502221310.4e00c062@posting.google.com...
> Hello people:
>
> I would like your knowledgeable opinion regarding the practice of
> cutting holes through things other than wood. In my case, I am
> wanting to cut two accurate holes (measuring 80mm in dia; 3 1/8")
> through a panel of thin sheet metal attached to high impact plastic,
> like the type used in making cabinets for electronics and PCs.
> Actually, I've given in to the idea of trying to get around *not*
> improving the airflow in an old Sony Vaio case for overclocking and
> will bite the bullet on this one (see thread:
>
http://www.google.ca/groups?q=insubject:Sony+author:Bruce+author:Gillis&hl=en&lr=&selm=2c942c97.0502041219.ff6042%40posting.google.com&rnum=1)
>
> After looking carefully at the piece, I believe that I will get better
> results with the holes if I leave the two materials together for the
> cut rather than doing each seperately. However, I don't know squat
> about hole saws. What grade of hole saw is best for this job? or if
> a hole saw is even recommended for this job?
>
> Thanks,
>
> Bruce

 

[Guest]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

Cutting large holes in system cases:

Fastest and best results (and most expensive):
Chassis punch; a Greenlee 3 1/8" punch, cost - over $200 US [requires
drilling a center hole, ~ 3/8"

Middle of the road (fairly fast and moderately expensive):
Hole saw [circle with toothed edge the diameter of the desired hole]
or cutter [center drill with adjustable cutter that can be fixed to desired
diameter on an arm] Either tool requires a drill press and clamps; position
of hole restricted by size of drill press

Least expensive, slowest; quality of results depends on how much time you
put into the job:
Hand nibbler [drill a 3/8" or so hole near the edge of the hole, insert
nibbler, chew through the metal, following the outline of the desired hole,
~ 1/16" inch per chew; then smooth with file, emery cloth, and/or Dremel
type power hand tool]

Not recommended: jig or sabre saw (leaves ragged edges and marred finish)
--
Phil Weldon, pweldonatmindjumpdotcom
For communication,
replace "at" with the 'at sign'
replace "mindjump" with "mindspring."
replace "dot" with "."

"Bruce Gillis" <brucekg78@yahoo.com> wrote in message
news:2c942c97.0502221310.4e00c062@posting.google.com...
> Hello people:
>
> I would like your knowledgeable opinion regarding the practice of
> cutting holes through things other than wood. In my case, I am
> wanting to cut two accurate holes (measuring 80mm in dia; 3 1/8")
> through a panel of thin sheet metal attached to high impact plastic,
> like the type used in making cabinets for electronics and PCs.
> Actually, I've given in to the idea of trying to get around *not*
> improving the airflow in an old Sony Vaio case for overclocking and
> will bite the bullet on this one (see thread:
>
http://www.google.ca/groups?q=insubject:Sony+author:Bruce+author:Gillis&hl=en&lr=&selm=2c942c97.0502041219.ff6042%40posting.google.com&rnum=1)
>
> After looking carefully at the piece, I believe that I will get better
> results with the holes if I leave the two materials together for the
> cut rather than doing each seperately. However, I don't know squat
> about hole saws. What grade of hole saw is best for this job? or if
> a hole saw is even recommended for this job?
>
> Thanks,
>
> Bruce

 

[Guest]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

"Phil Weldon" <notdisclosed@example.com> wrote in message
news:RcQSd.9009$x53.8977@newsread3.news.atl.earthlink.net...
> Cutting large holes in system cases:
>
> Fastest and best results (and most expensive):
> Chassis punch; a Greenlee 3 1/8" punch, cost - over $200 US [requires
> drilling a center hole, ~ 3/8"
>
> Middle of the road (fairly fast and moderately expensive):
> Hole saw [circle with toothed edge the diameter of the desired hole]
> or cutter [center drill with adjustable cutter that can be fixed to
> desired
> diameter on an arm] Either tool requires a drill press and clamps;
> position
> of hole restricted by size of drill press
>
> Least expensive, slowest; quality of results depends on how much time you
> put into the job:
> Hand nibbler [drill a 3/8" or so hole near the edge of the hole, insert
> nibbler, chew through the metal, following the outline of the desired
> hole,
> ~ 1/16" inch per chew; then smooth with file, emery cloth, and/or Dremel
> type power hand tool]
>
> Not recommended: jig or sabre saw (leaves ragged edges and marred finish)
> --
> Phil Weldon, pweldonatmindjumpdotcom

I have always found the Dremel Tool with a ceramic cutoff
wheel to do a great job with such cuts. I can have the hole
done and all cleaned up, faster than I can find and setup a
Greenlee punch.

Luck;
Ken

Hi Phil, good to see the hurricanes didn't get you. How's
your goat?

 

[jad]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

3/8 hole? a drill and a 3/8 metal / all material bit.


"Bruce Gillis" <brucekg78@yahoo.com> wrote in message
news:2c942c97.0502221310.4e00c062@posting.google.com...
> Hello people:
>
> I would like your knowledgeable opinion regarding the practice of
> cutting holes through things other than wood. In my case, I am
> wanting to cut two accurate holes (measuring 80mm in dia; 3 1/8")
> through a panel of thin sheet metal attached to high impact plastic,
> like the type used in making cabinets for electronics and PCs.
> Actually, I've given in to the idea of trying to get around *not*
> improving the airflow in an old Sony Vaio case for overclocking and
> will bite the bullet on this one (see thread:
> http://www.google.ca/groups?q=insubject:Sony+author:Bruce+author:Gillis&hl=en&lr=&selm=2c942c97.0502041219.ff6042%40posting.google.com&rnum=1)
>
> After looking carefully at the piece, I believe that I will get better
> results with the holes if I leave the two materials together for the
> cut rather than doing each seperately. However, I don't know squat
> about hole saws. What grade of hole saw is best for this job? or if
> a hole saw is even recommended for this job?
>
> Thanks,
>
> Bruce

 

[Guest]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

JAD wrote:
> 3/8 hole? a drill and a 3/8 metal / all material bit.

Hey JAD, "(measuring 80mm in dia; 3 1/8")"

Time to windex the monitor.


>
> "Bruce Gillis" <brucekg78@yahoo.com> wrote in message
> news:2c942c97.0502221310.4e00c062@posting.google.com...
>
>>Hello people:
>>
>>I would like your knowledgeable opinion regarding the practice of
>>cutting holes through things other than wood. In my case, I am
>>wanting to cut two accurate holes (measuring 80mm in dia; 3 1/8")
>>through a panel of thin sheet metal attached to high impact plastic,
>>like the type used in making cabinets for electronics and PCs.
>>Actually, I've given in to the idea of trying to get around *not*
>>improving the airflow in an old Sony Vaio case for overclocking and
>>will bite the bullet on this one (see thread:
>>http://www.google.ca/groups?q=insubject:Sony+author:Bruce+author:Gillis&hl=en&lr=&selm=2c942c97.0502041219.ff6042%40posting.google.com&rnum=1)
>>
>>After looking carefully at the piece, I believe that I will get better
>>results with the holes if I leave the two materials together for the
>>cut rather than doing each seperately. However, I don't know squat
>>about hole saws. What grade of hole saw is best for this job? or if
>>a hole saw is even recommended for this job?
>>
>>Thanks,
>>
>>Bruce
>
>
>

 

[jad]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

"David Maynard" <nospam@private.net> wrote in message
news:111pcsgj8guh653@corp.supernews.com...
> JAD wrote:
>> 3/8 hole? a drill and a 3/8 metal / all material bit.
>
> Hey JAD, "(measuring 80mm in dia; 3 1/8")"
>
> Time to windex the monitor.


OOOOps........on the other hand the cleaning of the monitor cleared up
things nicely. and here I thought I needed a new one.

OP -craftsman metal hole saw..with a dremal stone for clean up. but much
bigger than a 3/8in.(sigh) the largest one i have is only 2-1/2in..

i thought that sounded funny...the picture of a 3/8 hole saw didnt compute.
Picked a bad time to quit drinking coffee.


>
>
>>
>> "Bruce Gillis" <brucekg78@yahoo.com> wrote in message
>> news:2c942c97.0502221310.4e00c062@posting.google.com...
>>
>>>Hello people:
>>>
>>>I would like your knowledgeable opinion regarding the practice of
>>>cutting holes through things other than wood. In my case, I am
>>>wanting to cut two accurate holes (measuring 80mm in dia; 3 1/8")
>>>through a panel of thin sheet metal attached to high impact plastic,
>>>like the type used in making cabinets for electronics and PCs.
>>>Actually, I've given in to the idea of trying to get around *not*
>>>improving the airflow in an old Sony Vaio case for overclocking and
>>>will bite the bullet on this one (see thread:
>>>http://www.google.ca/groups?q=insubject:Sony+author:Bruce+author:Gillis&hl=en&lr=&selm=2c942c97.0502041219.ff6042%40posting.google.com&rnum=1)
>>>
>>>After looking carefully at the piece, I believe that I will get better
>>>results with the holes if I leave the two materials together for the
>>>cut rather than doing each seperately. However, I don't know squat
>>>about hole saws. What grade of hole saw is best for this job? or if
>>>a hole saw is even recommended for this job?
>>>
>>>Thanks,
>>>
>>>Bruce
>>
>>
>>
>

 

[Dino]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

when I did that a couple of years ago, I used a metal blade in a jigsaw and
then cleaned up all the edges with a rotary tool(Dremel). IE..I drew the
rough outline using a compass..used my largest drill bit to bore half a
dozen or so holes in various locations on the steel , got as close as I
could with the blade and then used a sanding drum to get right to my lines.

 

[Guest]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

JAD wrote:
> "David Maynard" <nospam@private.net> wrote in message
> news:111pcsgj8guh653@corp.supernews.com...
>
>>JAD wrote:
>>
>>>3/8 hole? a drill and a 3/8 metal / all material bit.
>>
>>Hey JAD, "(measuring 80mm in dia; 3 1/8")"
>>
>>Time to windex the monitor.
>
>
>
> OOOOps........on the other hand the cleaning of the monitor cleared up
> things nicely. and here I thought I needed a new one.
>
> OP -craftsman metal hole saw..with a dremal stone for clean up. but much
> bigger than a 3/8in.(sigh) the largest one i have is only 2-1/2in..
>
> i thought that sounded funny...the picture of a 3/8 hole saw didnt compute.
> Picked a bad time to quit drinking coffee.
>

Hehe

Well, it was just a space and a 1 off Not like you used English instead
of metric units and rammed a space craft into Mars, or anything like that.


>>
>>>"Bruce Gillis" <brucekg78@yahoo.com> wrote in message
>>>news:2c942c97.0502221310.4e00c062@posting.google.com...
>>>
>>>
>>>>Hello people:
>>>>
>>>>I would like your knowledgeable opinion regarding the practice of
>>>>cutting holes through things other than wood. In my case, I am
>>>>wanting to cut two accurate holes (measuring 80mm in dia; 3 1/8")
>>>>through a panel of thin sheet metal attached to high impact plastic,
>>>>like the type used in making cabinets for electronics and PCs.
>>>>Actually, I've given in to the idea of trying to get around *not*
>>>>improving the airflow in an old Sony Vaio case for overclocking and
>>>>will bite the bullet on this one (see thread:
>>>>http://www.google.ca/groups?q=insubject:Sony+author:Bruce+author:Gillis&hl=en&lr=&selm=2c942c97.0502041219.ff6042%40posting.google.com&rnum=1)
>>>>
>>>>After looking carefully at the piece, I believe that I will get better
>>>>results with the holes if I leave the two materials together for the
>>>>cut rather than doing each seperately. However, I don't know squat
>>>>about hole saws. What grade of hole saw is best for this job? or if
>>>>a hole saw is even recommended for this job?
>>>>
>>>>Thanks,
>>>>
>>>>Bruce
>>>
>>>
>>>
>
>

 

[Guest]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

"Ken Maltby" wrote
'Hi Phil, good to see the hurricanes didn't get you. How's your goat?'

Ken, thanks for asking: I've left South Florida for Atlanta; ice storms
rather than hurricanes.

The goat opted for the warmer climate!


--
Phil Weldon, pweldonatmindjumpdotcom
For communication,
replace "at" with the 'at sign'
replace "mindjump" with "mindspring."
replace "dot" with "."

 

[Guest]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

On Wed, 23 Feb 2005 14:06:58 -0600, David Maynard <nospam@private.net>
wrote:

>JAD wrote:
>> "David Maynard" <nospam@private.net> wrote in message
>> news:111pcsgj8guh653@corp.supernews.com...

>>>JAD wrote:
>>>
>>>>3/8 hole? a drill and a 3/8 metal / all material bit.

>>>Hey JAD, "(measuring 80mm in dia; 3 1/8")"

>>>Time to windex the monitor.

>> OOOOps........on the other hand the cleaning of the monitor cleared up
>> things nicely. and here I thought I needed a new one.
>>
>> OP -craftsman metal hole saw..with a dremal stone for clean up. but much
>> bigger than a 3/8in.(sigh) the largest one i have is only 2-1/2in..

>> i thought that sounded funny...the picture of a 3/8 hole saw didnt compute.
>> Picked a bad time to quit drinking coffee.

>Hehe
>
>Well, it was just a space and a 1 off Not like you used English instead
>of metric units and rammed a space craft into Mars, or anything like that.



>>>>"Bruce Gillis" <brucekg78@yahoo.com> wrote in message
>>>>news:2c942c97.0502221310.4e00c062@posting.google.com...

>>>>>Hello people:

>>>>>I would like your knowledgeable opinion regarding the practice of
>>>>>cutting holes through things other than wood. In my case, I am
>>>>>wanting to cut two accurate holes (measuring 80mm in dia; 3 1/8")
>>>>>through a panel of thin sheet metal attached to high impact plastic,
>>>>>like the type used in making cabinets for electronics and PCs.
>>>>>Actually, I've given in to the idea of trying to get around *not*
>>>>>improving the airflow in an old Sony Vaio case for overclocking and
>>>>>will bite the bullet on this one (see thread:
>>>>>http://www.google.ca/groups?q=insubject:Sony+author:Bruce+author:Gillis&hl=en&lr=&selm=2c942c97.0502041219.ff6042%40posting.google.com&rnum=1)
>>>>>
>>>>>After looking carefully at the piece, I believe that I will get better
>>>>>results with the holes if I leave the two materials together for the
>>>>>cut rather than doing each seperately. However, I don't know squat
>>>>>about hole saws. What grade of hole saw is best for this job? or if
>>>>>a hole saw is even recommended for this job?

>>>>>Thanks,

>>>>>Bruce

http://www.over-clock.co.uk/articles.php?action=show&showarticle=5

 

[Guest]

Archived from groups: alt.comp.hardware.pc-homebuilt,alt.comp.hardware.overclocking (More info?)

"dino" <whyme@help.com> wrote in message news:<DH1Td.14063$uO.490139@news20.bellglobal.com>...
> when I did that a couple of years ago, I used a metal blade in a jigsaw and
> then cleaned up all the edges with a rotary tool(Dremel). IE..I drew the
> rough outline using a compass..used my largest drill bit to bore half a
> dozen or so holes in various locations on the steel , got as close as I
> could with the blade and then used a sanding drum to get right to my lines.

I agree that there are a few tool options for this task. However, for
this job, I need to be fussy and don't want to f**k up the panel (I'll
likely never find a replacement) I am beginnning to think that my
best bet will be the handy dandy hole saw, as I have emailed some of
the major tool makers, ie., Milwaukee, DeWalt, Irwin, etc. All of them
are saying to go with the hole saw. And for accuracy, to use a drill
press. Sounds about right to me. Wish me luck.