Pip

Best way to punch IEC panel mount connector in boxes.
« on: August 22, 2015, 11:01:33 PM »
OK I have had enough. I can do all the various holes in my project boxes and they all come out great except for the venerable IEC Panel Connector! Does any one know of a solution that is available other than ordering boxes with it done by the manufacturer. Something like a Greenlee Punch or the like.

Yours Truly
Aching Hands
Pip
New York City
http://geosonixlab.com


dirtyhanfri

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #1 on: August 23, 2015, 02:16:56 AM »
I cut them with a Dremel, once the hole for the connector's body is done I place it and mark the screw holes

Actually they're almost the easiest for me
Working on it...

abbey road d enfer

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #2 on: August 23, 2015, 05:44:53 AM »
I cut them with a Dremel, once the hole for the connector's body is done I place it and mark the screw holes

Actually they're almost the easiest for me
What tool on the Dremel? How do you manage to cut straight? And how do you make the rounded corners? What material? Plastic, aluminium, mild steel, alloy...
How nice is it ending? Do you rear-mount or front-mount? Front-mount is easy, because it hides the ragged edges, but not always feasible.
Who's right or wrong is irrelevant. What matters is what's right or wrong.
"The important thing is not to convince, but to give pause for thought." (B. Werber)
Star ground is for electricians.

dirtyhanfri

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #3 on: August 23, 2015, 07:06:20 AM »
Just a cut disc holder, using cutting discs from eBay, nothing fancy. I use to work with aluminum enclosures. Cutting straight in such small dimensions isn't so hard at all (IEC sockets I use are 36x27mm. IIRC).

Never tried to do rounded corners as I mount them from the front side (from outside to inside)  and the edges stay covered, anyway, easy to do by hand with a file.

Ending is as nice as you want, again, using a file you can get smooth cuts, and due to dimensions it can be done in few minutes.
Working on it...

abbey road d enfer

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #4 on: August 23, 2015, 07:23:44 AM »
OK, should be useful to members.
Who's right or wrong is irrelevant. What matters is what's right or wrong.
"The important thing is not to convince, but to give pause for thought." (B. Werber)
Star ground is for electricians.

audiomixer

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #5 on: August 23, 2015, 04:42:13 PM »
I haven't tried it yet, but I am looking for a nibbler tool. it lets you follow irregular lines and takes sharp bites... you can get hand operated ones and air / electrical ones.

- michael

emrr

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #6 on: August 23, 2015, 04:52:36 PM »
Dremel with reinforced cutoff wheel.  File to clean/smooth/widen.  Takes longer to mark the dimensions than to cut.  15 minutes total? 

Exterior:
Best,

Doug Williams
Electromagnetic Radiation Recorders

"I think this can be better. Some kind of control that's intuitive, not complicated like a single knob" - Crusty

"Back when everything sounde

emrr

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #7 on: August 23, 2015, 04:53:25 PM »
You can buy a punch, but there are so many size variants amongst connectors, plus the punches run several hundred dollars last I looked. 

interior:
Best,

Doug Williams
Electromagnetic Radiation Recorders

"I think this can be better. Some kind of control that's intuitive, not complicated like a single knob" - Crusty

"Back when everything sounde

nielsk

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #8 on: August 23, 2015, 09:00:34 PM »
I scribe the outline using a home made stencil, use a step bit to drill out a hole to the edges of the outline, and a hand nibbler to cut out the rest, staying just shy of the outline, then clean up with a file.
Still a PIA, I would love to have a punch for this, too...

Rochey

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #9 on: August 23, 2015, 10:44:18 PM »
There's a lot to be said for getting a small Chinese 3020 CNC for this kind of stuff.

I tried with a zen tools works 7x7 CNC but the frame wasn't strong enough.

On a serious note - a decent hole punch is a lot of coin. ($100+ ).  A small CNC would give you much more flexibility, but I think you'd have to use aluminium.

Cheers

R
Expat Audio Home: http://www.expataudio.com


gyraf

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #10 on: August 24, 2015, 07:27:14 AM »
This one works well for integral-fuse IEC sockets: http://uk.rs-online.com/web/p/punch-die-combinations/0542302/

I've used these for a long time now...

Jakob E.
..note to self: don't let Harman run your company..

dirtyhanfri

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #11 on: August 24, 2015, 02:24:58 PM »
There's a lot to be said for getting a small Chinese 3020 CNC for this kind of stuff.

I tried with a zen tools works 7x7 CNC but the frame wasn't strong enough.

On a serious note - a decent hole punch is a lot of coin. ($100+ ).  A small CNC would give you much more flexibility, but I think you'd have to use aluminium.

Cheers

R

Exactly what I did, didn't try with aluminium, still learning about machining and PCB engraving, but the main purpose is make pannels.

Just done a few pcbs and I got to say this machine pays itself, the best invest I've ever done.
Working on it...

Gold

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #12 on: August 25, 2015, 03:53:23 AM »
I burned out four Dremels before I bought a Foredom flexible shaft rotary tool. I'm probably too impatient but the rotary tool is very useful for all sorts of things.

http://www.foredom.net/rotarytools.aspx

Andy Peters

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #13 on: August 25, 2015, 05:58:06 PM »
I burned out four Dremels before I bought a Foredom flexible shaft rotary tool. I'm probably too impatient but the rotary tool is very useful for all sorts of things.

http://www.foredom.net/rotarytools.aspx

Looks great, and you can even do horse dentistry!
"On the Internet, nobody can hear you mix a band"

Gold

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #14 on: August 25, 2015, 06:21:21 PM »
I have the TX motor with the regular (not square) drive. If I was to do it over I would have gotten the LX low speed, high torque motor. It would be more useful for more kinds of metal. I may swap the TX out at some point but I'm trying to tell myself that what I have is fine, which it basically is.

leadbreath

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #15 on: August 25, 2015, 07:04:50 PM »
rectangular chassis punch as previously mentioned, you'll never look back...
f**k marlbro's and weed ill stick to smoking germanium and silicon


G-Sun

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #17 on: April 30, 2016, 11:18:30 AM »
This one works well for integral-fuse IEC sockets: http://uk.rs-online.com/web/p/punch-die-combinations/0542302/

I've used these for a long time now...
How do these work?
HJFP2, ssl9k, Harrison Ford Filters
My music

warpie

Re: Best way to punch IEC panel mount connector in boxes.
« Reply #18 on: April 30, 2016, 02:28:23 PM »
This one works well for integral-fuse IEC sockets: http://uk.rs-online.com/web/p/punch-die-combinations/0542302/

I've used these for a long time now...
How do these work?

You can get the idea here. https://www.youtube.com/watch?v=D44z72iRUgU


G-Sun

HJFP2, ssl9k, Harrison Ford Filters
My music