Faceplate hole for VU meter??

[Matt C]

How do folks usually go about making a large hole in a 19" chassis faceplate for a big VU meter? Is it possible to get a punch that big? Am I better off just ordering a custom-machined faceplate? any advice is much appreciated.

 

[Rob Flinn]

If I am not getting a professionally made panel I mark out with a compass, use plenty of masking tape, drill a few 10mm holes then get my jigsaw to work. Finish with a half round file.

 

[scott2000]

Hole saw?

 

[JohnRoberts]

for a hole that big you may need to take several bites using a smaller punch. I don't think Greenlee makes anything that big.

JR

 

[thelivingroom]

In the past I would use a drill press and bi-metal hole saw bit. These days it’s cheap enough to get something laser cut by a place like SendCutSend that my poor drill press probably feels lonely.

 

[gyraf]

In aluminium, I use a simple handheld wood-router running in an attached 4mm acrylic jig with an appropriate cutout

 

[abbey road d enfer]

It depends very much on the material and the shape of the hole.
I have found that this type of bell-saw is extremely capable, even in mild steel. However it requires a very good drill press with proper clamping. You can't use them with hand-held tools.
https://fr.aliexpress.com/item/1005...4p_id=2025031104072163946148529040000190060_3

 

[rock soderstrom]

In aluminium, I use a simple handheld wood-router running in an attached 4mm acrylic jig with an appropriate cutout

+1

I do this similarly for all my larger cutouts, aluminum is just shiny wood. It's not for the faint-hearted, wear protective gear.

I make round cut-outs with a special (circle) jig for the edge router and templates for square cut-outs with thin LEGO bricks, no joke.

Edit: That's how I started (on my washing machine), I've optimized the process a bit since then.

' https://groupdiy.com/threads/diy-pr...mps-buffers-or-microphones.84324/post-1098005

 

[Matt Syson]

Remember that the VU meter you are fitting must be designed for the panel material as STEEL panels mess up the balistics of moving coil meter movements. Aluminium is not a problem.

 

[thelivingroom]

In aluminium, I use a simple handheld wood-router running in an attached 4mm acrylic jig with an appropriate cutout

I’m surprised I haven’t tried that, as what @rock soderstrom said, it’s just shiny wood. I’ve used my table saw with 80-tooth finish blade to make straight cuts on sheet aluminum, and miter saw for angle, round, and square tube many times with great results.

 

[gyraf]

Found this by a forum search:

https://groupdiy.com/threads/heavy-duty-sheet-metal-nibbler-on-steroids.60887/page-2#post-772120

Picture:
https://groupdiy.com/attachments/g10-meter-routing-jpg.37983/

/Jakob E.