Hole punch

[Walt]

In the process of building a new under dash console and need a way to punch holes with the flat on one side, what would be the best tool , that wont break the bank, to use for this?
Its .04 aluminum.
Thanks
Walt

[Avalanche325]

There are hand held punches for sheet metal for smaller holes. You can get them from Amazon. I haven't used one.
For larger holes, Greenlee makes manual ones that you use a wrench on. There are probably cheap versions if you don't intend to make a living with it. Search for Greenlee punch and the cheap ones will come up also.

Of course, drills and hole saws are the cheap and dirty way.

[BEAR-AvHistory]

I am a punch & drill person. Punch a dimple & drill the hole. Are you going to cover the Console?

[Walt]

Yes, will cover with vinyl, i normally just drill but for my switchs i need the flat on one side so they dont turn.
Walt

[Murd]

I’d probably use a combo of smaller drill bit, jig saw and dremel.

[Cobradavid]

I’d probably use a combo of smaller drill bit, jig saw and dremel.

^^ What he said

[miller7448]

Two cherished tools passed down from my steamfitter father. Very handy on the build. Already told me son if he does not hang on to them once I pass them down both my father and I will come back from the grave.

114148

[davekp]

You're spending how many thousand dollars on this build?
Do it right and get the right punch. Especially
because you want all the holes aligned well.

[edwardb]

In .040 aluminum, holes with flats for switches take about 5 minutes with an undersize drilled hole and a couple of small files including a half-round. Needle files if the holes are small. I like tools as much as the next guy (and have a basement and garage to prove it) but thin 6061 aluminum is super easy and fast to work with IMHO.

[Big Blocker]

Greenlee makes a set of punches for electrical conduit knockouts . . . might be a bit large for switches though.

Check the electronic suppliers for "chassis punches" for project boxes, they usually come in switch mount sizes and configurations.

Doc

[Walt]

Ok, thanks for the help guys!
Walt