I hate cutting IEC connectors on chassis

[rp]

The exploding Dremel cut-off wheels

Till now I thought it was just me and a lack of some special dremeling skill

You guys make it too hard, 3/4 hole in middle, nibble and file. Handles those slanted corner IECs too, but you need a narrow file the width of the corner. I made up a little cardboard template that fits over the IEC with marks for squaring up. Nibbler will only work with alu unless you have he-man hands, even then. The good part is there's no chance of slipping and scratching up the chassis like w/ a dremel. But you can easily over nibble. Don't over nibble, the IECs have hardly any lip, serious serious cursing ensues.

[Phil_S]

I can't believe I didn't know about optical center punches. I'm sorta blown away. They are a little pricey, though.
Look at this: http://www.youtube.com/watch?v=k6Imt9vgDqE BTW, my favorite style of instructional video -- the guy never says a word!

Thinking about this, simply employing a good magnifying glass when placing the punch would really enhance accuracy. Since we don't have need for extreme precision, this would certainly be a move in the right direction.

Thanks, davent, for posting.

The budget for a optical punch feels out of reach at the moment. I think, however, I already have everything I need to make a router template and maybe I'll invest the time to do that when I have to cut my next IEC hole.

[Colossal]

Router jig works great. I make a template overlay to locate and center the mounting holes for the socket. Drill them out, then attach the jig. Drill out a starter hole near a corner and then route out the socket hole with a 1/4" flush-cutting bit. Perfect every time. As mentioned, you have to be careful about which IEC socket you make your template for as there are some tolerance issues!

[cbass]

Router jig works great. I make a template overlay to locate and center the mounting holes for the socket. Drill them out, then attach the jig. Drill out a starter hole near a corner and then route out the socket hole with a 1/4" flush-cutting bit. Perfect every time. As mentioned, you have to be careful about which IEC socket you make your template for as there are some tolerance issues!

Make sure your chassis is aluminum first

[rp]

So I should not fear router bits and alu chassis??? Just normal decent quality like Ryobi bits? Just go at it like wood? I must get my courage up.

[Structo]

Never knew about optical center punches.

I use a cheap spring loaded center punch.

You center it on the dot on the template and push down until it fires.
I usually do it twice for a good dimple.

Also good for breaking car windows.

[img:500:73]http://ecx.images-amazon.com/images/I/31XVAWXASDL.jpg[/img]

http://www.amazon.com/General-Tools-Bea ... nter+punch

[Colossal]

So I should not fear router bits and alu chassis??? Just normal decent quality like Ryobi bits? Just go at it like wood? I must get my courage up.

Cuts like buttah. I usually use 0.09" aluminum chassis. Make a nice MDF jig or have a SS one machined and let the tool do the work. Wish I had a photo to attach but the results are excellent. Looks punched when it's done. Dead clean. Carbide bit is fine and it's done in about 10 seconds.

[Phil_S]

I have the caveman era center punch. With proper care, it can work very well. Easy to work. No moving parts

[Tillydog]

Dead clean. Carbide bit is fine and it's done in about 10 seconds.

Router with a carbide cutter has worked fine for me on Al, but I always run it on the slowest speed and take a light cut.

And you'll be finding "glitter" all over your 'shop for years!

[passfan]

I bought a 3/4" square punch from greenlee for about 80.00 a few years back. I take 3 bites with it and clean the hole with a file. 5 minutes tops.

[Phil_S]

I bought a 3/4" square punch from greenlee for about 80.00 a few years back. I take 3 bites with it and clean the hole with a file. 5 minutes tops.

I've never used a punch of any type. The hole needs to be 1" x 3/4". How does this work with a square punch? Are you able to place it on the work in a second location to finish the last 1/4"?

[katopan]

+ another for the jigsaw. 3 minutes tops including drilling the corner holes. You just need to move slowly and really watch closely to not go over the line.

[mrn1ngstr]

I just did this for the first time with a nibbler, dremel and a file. Glad to see that Im not the only one that really hates this... Dremel definitely cleaned the ugly hole up.

[rock_mumbles]

Al chassis and jigsaw with a template from a blown up computer power supply ... 5 minutes or so

[RCGPNY1]

Just to play devil's advocate...And I know it's more convenient to have a removeable ac wire but....for years and years we have been dealing with amps(Fender, Marshall...just about EVERYTHING) with an attached cable.
Drill a hole, get a strain relief - Done!