Hole cutting

[Fresh_Start]

Anybody have a punch for the strain-relief clip on the power cord? In the past, I just drilled a smaller round hole, then used a rat file/flat file to enlarge the hole and make the flat part of the "D." It was very time consuming, but the only D-shaped punch I've seen was super expensive. Any suggestions?

IEC outlet?

Seriously, I hate those vintage strain relief things and getting them into that damned hole.

Cheers,

Chip

[plexi50]

This is my best friend! And of course the dremel tool. No more cutup hands or burns /

The step drill is great and was only $5.00 on Ebay 2 years ago. You need a 1/2 drill for it though

[Ritchie200]

Question about the step drill.  I use it all the time but it always leaves a large burr.  At times it's very hard to get at to de-burr.  (Most chassis I drill are steel).  Is there a trick to using these things?

There is also a deburr tool you can get...  http://www.kbctools.com/can/main.cfm  go to page 566

+1 on the deburring tool.  I can't tell you how many holes I deburrred as an apprentice Tool and Die Maker with this tool.  The one with the "V" blade will do both sides at the same time if it is soft, like Al.  If it is steel, use the single angle blade and do it from both sides - don't try to angle it.  It will leave a very nice looking bevel - say goodbye to sandpaper/grinder rash.  Very easy to use and the blades will last longer than the number of amps you can build in a lifetime.  When you get good at it you can deburr a hole in about 5-10 seconds.  Highly recommended.

Jim