Making Square Holes In Sheet Metal

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. Extend the combination square blade until it meets one side of the drilled hole. This is a simple diy solution to broaching odd shaped holes in metal.

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

Making square holes in sheet metal.

You start off by drilling a small diameter pilot hole and then drill gradually larger holes until you get. Now it s time to use that center punch. Use a hydraulic press to gradually and smoothly increase pressure until the broach is forced through the hole cutting material and forming a square. 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.

Move the combination square and repeat the process to mark a straight line on each side of the drilled hole forming a square. This will create dimples in the sheet. The multi positional guides are 1 aluminum angles held in position with clamps i use both c clamps and cleco s. Drilling a hole in sheet metal with a twist drill is a rather straightforward operation.

Insert the broach and ensure it lines up at 90 degrees from the work peice or the hole will be crooked. Next use a compass to outline the edge of the hole. Put your ink to the use and mark the hole center. Drill a hole in the metal close to but smaller than the finished hole size.

Use either a fine tipped sharpie or a metal scriber depending on your tolerances. Set the base of a combination square on one side of the material. How to use chisels instead of files to cut a share hole for carriage bolts. Use your center punch to strike at the center of the hole.

Drag an awl along the end of the combination square blade. The bit used is a 1 8 single flute type. Here are some methods depending on the tools you have and the size of the square hole and the thickness of the sheet metal. Simple tool to drill square holes.

At first locate the center of the whole. The router is just a standard off the shelf ryobi router mounted under a home made router table. Super easy tip in this video we show you how to drill a hole for a carriage bolt. Blacksmithing for beginners cutting a square hole in sheet metal.

How to drill a square hole.

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