Best way to cut an Aluminum Chassis?

[Scott_F]

I'm going to cut one of my 15 watt chassis and put in Matchless 30 watt transformers and 2 more EL84 power tubes. So, gurus, what's the best way to cut holes and enlarge power transformer cutouts?

Thanks.

 

[casblah]

Re: Best way to cut an Aluminum Chassis?

How big of a hole do you want to make?

 

[kmcguitars]

Re: Best way to cut an Aluminum Chassis?

Best thing I can think of are Aviation snips? Worked great!! Back in H.S.
metal shop. Maybe even a sawsall with the right blade.

 

[casblah]

Re: Best way to cut an Aluminum Chassis?

The best way to do tube holes is to use some type of chassis punch. You'd need to drill a "pilot" hole of some type, then bolt the assembly together and use a wrench to draw the punch thru.

 

[RGN]

Re: Best way to cut an Aluminum Chassis?

A a hand-held hydraulic punch like what you would use to make cut-outs on a large electrical box would work great.

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=7530654327&category=73117&ssPageName=WDVW&rd=1

Aluminum is pretty easy to cut, you could use a hole saw bit on a drill too...

 

[casblah]

Re: Best way to cut an Aluminum Chassis?

Cool link. Greenlee is the shiznit in punches!

 

[casblah]

Re: Best way to cut an Aluminum Chassis?

Though that kit is not easy on the wallet.

 

[aleclee]

Re: Best way to cut an Aluminum Chassis?

You might shoot James Peters an email. I believe my 3CP1 has an aluminum chassis.

 

[Scott_F]

Re: Best way to cut an Aluminum Chassis?

EL84 sized. size of a normal 9 pin preamp tube socket. Can't remember the exact size. I'd have to go measure.

 

[Scott_F]

Re: Best way to cut an Aluminum Chassis?

Hole punch.... hmm... let me check the hardware store. All I'd need would be one to do the preamp/EL84 tubes and another to do the 6L6/5AR4 tubes.

 

[Stratman]

Re: Best way to cut an Aluminum Chassis?

Scott

Plasma torch

or Water jet (That stuff cut titanium)

 

[Stratman]

Re: Best way to cut an Aluminum Chassis?

What till you try to bend it...

It breaks rather easily

PS: Scott have you tried welding alumium yet?

 

[Scott_F]

Re: Best way to cut an Aluminum Chassis?

Dude, I have some nice Aluminum chassis' for the 15 watter that was laser cut somewhere. I just want to mod it to run 4xEL84 instead of two. So, I gotta punch two more holes for the extra power tubes. Then I'll have to enlarge the holes that the PT and OT drop into.

I'm *not* trying to start from scratch. If my 30 watter works out, I'll get the guy to make my next few chassis' with the extra holes.

 

[accipiter]

Re: Best way to cut an Aluminum Chassis?

Maybe a hole saw kit is what you need?

http://www.toolking.com/milwaukee/view.asp?id=349

Or maybe a step drill bit to bore out the holes?

http://www.boschtools.com/accessories/accessories-detail?H=176252&G=54720&T=2&D=True

 

[beandip]

Re: Best way to cut an Aluminum Chassis?

well, seems like you got enough advice here to figure something out.

 

[Rich_S]

Re: Best way to cut an Aluminum Chassis?

Believe it or not, and lot of the AX84/18_Watt guys drill tube-socket holes with regular wood-boring spade bits. They actually do a good job in aluminum; I just did a few in my 1/8" aluminum pedalboard top when I didn't have the right size Greenlee punch.

The problem with Greenlee punches is that they're expensive. If you're only doing a few holes, buy a spade bit at Home Depot. Look for the kind with a little spur on the outside, rather than the square corner.

For transformer holes, I would recommend drilling the corners with a large twist drill of spade bit (that matches the xfrmer's corner radius) then connect the holes with a jig saw (plus a bit of filing) or with a nibbling tool. A nibbler that will cut chassis is available at Radio Shack for ~$10. I used it on my DIY 13-Watter for the power connector hole and such.

 

[Tom M]

Re: Best way to cut an Aluminum Chassis?

Sawzall.

Fixes everything!!!