CHASSIS HOLE CUTTING GONE WAY WRONG

[ViperDoc]

Let's just say that desperation and regret are often joined at the hip. While on lockdown yet determined to make progress on my current amp build, I took a big risk at the local hardware store on the only available tool capable of making a large-enough filter capacitor hole--this piece of f^cking hot garbage.



The tool is not in the picture BECAUSE IT'S AT THE BOTTOM OF MY DUMPSTER after breaking in the middle of the operation and creating the most Picasso-esque ellipse that cheap-ass money can buy. What a piece.

I should have known that a fly-cutter would cut metal like a retarded chimp, but HEY, I WAS PASSIONATELY ENTHUSIASTIC!!! I even used a drill press, hey!

I think I will try a carbide hole saw next. Any more surefire recommendations? Y'all who laser cut these things you have my highest admiration and props, I'm just not likely to use something like that enough to justify.

Thanks as always.

[drew]

With a thread title like this, I was expecting, at a minimum, blood loss.

You're trying to make a hole for a can cap? In steel or aluminum? What about figuring out how big a square or rectangle you would need for all the terminals to clear, drill small holes at the corners then use a Dremel with a cutting wheel to make the straight cuts to connect the holes?

[ViperDoc]

This is a steel Valvestorm project chassis. It was beautiful until I ruined it. Life will, of course, go on, but I think I'd like to shoot for a round hole.

[thetragichero]

mine went away after trying to use it in wood, so i can't even imagine it on steel
got a knockout punch set from harbor freight for less than thirty bucks. sometimes i need to bore it a bit more with a step bit but those punches are nice

[wpaulvogel]

Greenlee chassis punches are the best thing around for what you want to do. I have a 3/4 inch and a 1 1/16 inch for tube sockets and cap cans. Best $$$ I ever spent for large chassis holes.

[Phil_S]

You've already admitted to your act. Post a picture. That won't make it any worse. You may think it is beyond salvage, but someone else may give you a path forward. I'm thinking something not too ugly and ultimately functional.

[ViperDoc]

I will. It's definitely usable, it's just fugly. No one will see it, so I'll use a different tool and move on.

[EDIT: I just watched a video on Greenlee knockout punches, I've never seen anything like that before. THAT"S COOL! The only problem with this with my current hole is I'm enlarging a prexisting hole non-concentrically, so these would not work for that. I suppose I could just relocate the new center.]

[jujudubluz]

+1 ON GREENLEE

[studiodunn]

+1 for pictures of the carnage

I use stepper bits and haven’t had any issues. Burr clean up is the only real downside, but being able use my drill press is a huge plus.

[pompeiisneaks]

I used stepper bits for a long while, but have accidentally gone too far once or twice, which really sucked. I do have punches now that I got from harbor freight and they do the job most of the time.

~Phil

[dorrisant]

You could do it like this... No holes required.

https://ampgarage.com/forum/viewtopic.p ... 0&start=15

[pompeiisneaks]

No holes required... for the caps yes... I see those tube sockets hiding in there

~Phil

[dorrisant]

Phil... original post... "large filter cap hole".

[dorrisant]

What size hole do you need? Give me a part number for reference. Post some pics of your disaster. I may be able to help with a band-aid type solution.

[pompeiisneaks]

Phil... original post... "large filter cap hole".

I know, I should have put the sarcasm tag on there

I'm just kidding!

BTW I have used that type of inside filter cap mounting style and love it.

~Phil