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cowboyro
Premium Member
join:2000-10-11
CT

cowboyro to Inssomniak

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to Inssomniak

Re: Cutting square hole into steel?

Cut a rough hole with a rotary tool and a cutting disc. Finish with a file. Works like a charm, probably 30 min total.

Inssomniak
The Glitch
Premium Member
join:2005-04-06
Cayuga, ON

Inssomniak

Premium Member

I would only be doing a handful.
What about a cross slide milling vice on a drill press? I don't need to be fast and an end mill could cut it slowly with good precision using the mill vice?

cb14
join:2013-02-04
Miami Beach, FL

cb14 to cowboyro

Member

to cowboyro
+1. A regular angle grinder with a very thin disc for metal cutting will do it.
TheMG
Premium Member
join:2007-09-04
Canada
MikroTik RB450G
Cisco DPC3008
Cisco SPA112

TheMG to cowboyro

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said by cowboyro:

Cut a rough hole with a rotary tool and a cutting disc. Finish with a file. Works like a charm, probably 30 min total.

This. I've done it plenty of times before, even for round and odd shaped holes too.

Mark out your hole, cut with rotary tool (aka "Dremel") just a tiny bit smaller than the marks, then finish off with a file until you just touch the marks. You'll have a nice looking square hole in no time.