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Panel punch

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mrspudandcompany(at)veriz
Guest

Posted: Tue Jun 29, 2010 3:44 pm Post subject: Panel punch

Does anyone on the list have a 3 1/8" panel punch that you might be willing

to loan out?  I have a set of Greenly Punches but do not have one this

large.  I need to punch about 3 instrument holes in my panel and I feel the

punch is the best way to go.  The panel is light gauge aluminum, so will be

very easy to punch.  I have considered using a hole saw, but I have never

been able to make a nice clean hole with this method.



Any help would be appreciated.



Roger Curtis

Upton, MA

Allen Fulmer

Joined: 10 Jan 2006
Posts: 79
Location: Alexander City, AL

Posted: Tue Jun 29, 2010 5:36 pm Post subject: Panel punch

I have one you would be welcome to borrow.  3-1/8 on one side, 2-1/4 on the

other.  Kind of heavy but maybe one of those "if it fits it ships" USPS

boxes wouldn't be too much.



Allen Fulmer

Alexander City, AL 35010



--

_________________
RV7 QB Fuselage
Eggenfellner H6 on orde
N808AF reserved
Alexander City, AL

rhdudley1(at)bellsouth.ne
Guest

Posted: Tue Jun 29, 2010 5:51 pm Post subject: Panel punch

Hi Roger,



When I did my RV-6A panel some years ago, I rented a punch from Bob Avery 

for a nominal fee. It  cut both the typical instruments sizes.



Regards,



Richard Dudley

---

fvalarm(at)rapidnet.net
Guest

Posted: Tue Jun 29, 2010 7:38 pm Post subject: Panel punch

A technique I use for a cleaner hole when using a large hole saw is to drill

the pilot hole first. Then put a standard drill bit into the hole saw

reversed so that the flutes cannot work the pilot hole wider and wider.  You

may also use a scrap piece of steel rod (1/4" on my hole saw).  The idea is

to not enlarge the pilot hole as the larger part of the hole saw does it's

thing. Of course clamp it tight and use a sharp hole saw for best results.

Clean up with a high speed rotary deburing bit on a die grinder.



Bevan



--

icubob(at)gmail.com
Guest

Posted: Wed Jun 30, 2010 2:22 am Post subject: Panel punch

i used a holesaw that i bought at ace. it worked perfect on my 1/16'' thick alum. i used one that mounted rigid on the center drill. more expensive ones that allowed substitution of sizes didnt work as well [i bought them too]. i cut my whole panel with 2 sized holes and each was perfect. buy one and try it on scrap first.

   bob noffs

 On Tue, Jun 29, 2010 at 5:30 PM, ROGER & JEAN CURTIS <mrspudandcompany(at)verizon.net (mrspudandcompany(at)verizon.net)> wrote:

 [quote]--> AeroElectric-List message posted by: "ROGER &  JEAN CURTIS" <mrspudandcompany(at)verizon.net (mrspudandcompany(at)verizon.net)>

 

Does anyone on the list have a 3 1/8" panel punch that you might be willing

to loan out?  I have a set of Greenly Punches but do not have one this

large.  I need to punch about 3 instrument holes in my panel and I feel the

 punch is the best way to go.  The panel is light gauge aluminum, so will be

very easy to punch.  I have considered using a hole saw, but I have never

been able to make a nice clean hole with this method.



Any help would be appreciated.

  utilities such as List Un/Subscription,

 www.matronics.com/Navigator?AeroElectric-List" target="_blank">http://www.matronics.com/Navigator?AeroElectric-List

 ronics.com/" target="_blank">http://forums.matronics.com

 Matt Dralle, List Admin.

 =====



[b]

Dennis Johnson

Joined: 10 Jan 2006
Posts: 89
Location: N. Calif.

Posted: Wed Jun 30, 2010 7:39 am Post subject: Panel Punch

EAA has a great tutorial video on a clever way to use a hole saw to make  nice holes in an instrument panel.

  

 http://www.eaa.org/video/homebuilders.html

  

 It's in the "General" tab, near the bottom of the list.

  

 Dennis

   [quote][b]

email(at)jaredyates.com
Guest

Posted: Wed Jun 30, 2010 8:54 am Post subject: Panel punch

Check out the video in the EAA's hints for homebuilders:



http://www.eaa.org/video/homebuilders.html

[/url]There is one about using a hole saw for instrument panels, and if I remember correctly, he uses a piece of pre-drilled plywood above the aluminum to align and steady the saw.  It's been a while since I watched it though.

 

On Wed, Jun 30, 2010 at 6:19 AM, bob noffs <icubob(at)gmail.com (icubob(at)gmail.com)> wrote:

[quote] i used a holesaw that i bought at ace. it worked perfect on my 1/16'' thick alum. i used one that mounted rigid on the center drill. more expensive ones that allowed substitution of sizes didnt work as well [i bought them too]. i cut my whole panel with 2 sized holes and each was perfect. buy one and try it on scrap first.

    bob noffs

 On Tue, Jun 29, 2010 at 5:30 PM, ROGER & JEAN CURTIS <mrspudandcompany(at)verizon.net (mrspudandcompany(at)verizon.net)> wrote:

  	  Quote: 	
		  --> AeroElectric-List message posted by: "ROGER &  JEAN CURTIS" <mrspudandcompany(at)verizon.net (mrspudandcompany(at)verizon.net)>

  

Does anyone on the list have a 3 1/8" panel punch that you might be willing

to loan out?  I have a set of Greenly Punches but do not have one this

large.  I need to punch about 3 instrument holes in my panel and I feel the

  punch is the best way to go.  The panel is light gauge aluminum, so will be

very easy to punch.  I have considered using a hole saw, but I have never

been able to make a nice clean hole with this method.



Any help would be appreciated.

   utilities such as List Un/Subscription,

 [url=http://www.matronics.com/Navigator?AeroElectric-List]www.matronics.com/Navigator?AeroElectric-List" target="_blank">http://www.matronics.com/Navigator?AeroElectric-List

  ronics.com/" target="_blank">http://forums.matronics.com

 Matt Dralle, List Admin.

 =====







ist" target="_blank">http://www.matronics.com/Navigator?AeroElectric-List

tp://forums.matronics.com

_blank">http://www.matronics.com/contribution



	
[b]

mrspudandcompany(at)veriz
Guest

Posted: Wed Jun 30, 2010 8:54 am Post subject: Panel Punch

Thanks everyone for the helpful hints on punching  instrument holes.  My opinion is that the best method is using a punch of  the correct size, however the EAA video, using a hole saw, appears to be a  viable alternative.

  

 Again, thanks,

  

 Roger

   [quote][b]

bbradburry(at)bellsouth.n
Guest

Posted: Wed Jun 30, 2010 1:33 pm Post subject: Panel Punch

I think someone said that they would send you a punch.  If not and you still need one, let me know.  My panel is .090 and these die worked on it.  You do have to squeeze, release, rotate, squeeze on this .090 thickness.  It would really work like a breeze on a thinner panel.  And you will need something to drill the center hole with.  A step drill works best for that.  

   

Bill B  

         

  

From: owner-aeroelectric-list-server(at)matronics.com [mailto:owner-aeroelectric-list-server(at)matronics.com] On Behalf Of Roger

 Sent: Wednesday, June 30, 2010 12:53 PM

 To: aeroelectric-list(at)matronics.com

 Subject: Panel Punch  

  

     

Thanks everyone for the helpful hints on punching instrument holes.  My opinion is that the best method is using a punch of the correct size, however the EAA video, using a hole saw, appears to be a viable alternative.  

    

   

    

Again, thanks,  

    

   

    

Roger  

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nuckolls.bob(at)aeroelect
Guest

Posted: Thu Jul 01, 2010 6:19 am Post subject: Panel punch

There is one other technology for panel fabrication that

some of you may wish to consider. Many fabricators of

flat sheet products can take your CAD drawings and convert

them directly into finished product.



Some years ago I did this panel layout for a C-120



http://aeroelectric.com/Pictures/Misc/120PANEL.pdf



I took a sheet of .125" aluminum and the .dxf file

for the drawing to a local CNC shop and for just over

$120 they cut me a panel that was accurate to better

than .001" all around.



Had I thought about it beforehand, I could have had

lettering engraved directly into the panel. After

having the panel anodized, the lettering can be filled

with colored, stick-enamels of choice.



I've built a number of devices for HBC, not the

least of which was this recovery parachute controller:



http://aeroelectric.com/Pictures/Misc/Recovery_Parachute_Controller_2.jpg



In this case, I e-mailed the drawing to a California

firm who cut me two engraved overlays with lettering,

beveled edges and all thru holes. I think two placards

were about $200.



Very low cost software like TurboCAD will produce the

necessary files for your panels, circuit breaker, and

switch panel overlays. The end results can look quit

professional.

   Bob . . .

mrspudandcompany(at)veriz
Guest

Posted: Fri Jul 02, 2010 4:54 pm Post subject: Panel punch

 	  Quote: 	
		   I have one you would be welcome to borrow.  3-1/8 on one side, 2-1/4 on 

 the

 other.  Kind of heavy but maybe one of those "if it fits it ships" USPS

 boxes wouldn't be too much.



 Allen Fulmer

 Alexander City, AL 35010


	




Allen,



I tried to contact you off line but did not get a response.  I would like to 

take you up on your offer to let me borrow your punches.  I will be happy to 

pay the Flat Rate USPS postage both ways.



If you have changed you mind about loaning the punch, please let me know and 

I will make other arrangements.



Thanks,



Roger

mrspudandcompany(at)veriz
Guest

Posted: Wed Jul 07, 2010 1:56 pm Post subject: Panel punch

 	  Quote: 	
		   Does anyone on the list have a 3 1/8" panel punch that you might be 

 willing

 to loan out?  I have a set of Greenly Punches but do not have one this

 large.  I need to punch about 3 instrument holes in my panel and I feel 

 the

 punch is the best way to go.  The panel is light gauge aluminum, so will 

 be

 very easy to punch.  I have considered using a hole saw, but I have never

 been able to make a nice clean hole with this method.



 Any help would be appreciated.



 Roger Curtis

 Upton, MA


	




 	  Quote: 	
		   I have one you would be welcome to borrow.  3-1/8 on one side, 2-1/4 on 

 the

 other.  Kind of heavy but maybe one of those "if it fits it ships" USPS

 boxes wouldn't be too much.



 Allen Fulmer

 Alexander City, AL 35010


	




        Allen,



        Thank you for the loan of your punch.  I can't immagine, short of

        setting the panel up on a milling machine, making instrument holes

        as nice, smooth, round, easy, and precisely placed, as can be

        accomplished with the simple punch.



        This is what it is all about, "Builders helping Builders"



        Great forum!



        Roger

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