Cutting Through Metal

[bainbrig]

I want to cut a fair-sized hole in a metal 'box', possibly 1.5mm thick, probably just mild steel. (Sorry to be vague).

What's the best way? Drilling holes then inserting a hacksaw seems possible, but would take ages! Is there anything easier on the market?

Ta.

BillB

[melv16]

https://www.bpfonline.co.uk/search.asp?catid=10751
Makes sure you get one for cutting through metal.

[alavahalf]

Get a metal cutting blade for your jigsaw or angle grinder. 1.5mm should be fairly simple.
As you say, just mark it out and drill the corners first.

[Fatalbertfixer]

How big a hole and what shape?

[The Builder]

I would do what Homer suggested ........... drill a hole in each corner and cut with one of these...

https://www.screwfix.com/p/erbauer-erb666grd-750w-4-angle-grinder-220-230v/5224j

[bainbrig]

About 4”x 1” Fatalbert.

Builder - that Screwfix one looks just the job - I was looking at a similar Bosch one for £85 (and that didn’t have a battery!)

BB

[Hymie]

Messing about, making small projects, I often have the need to cut holes of various shapes and sizes in both plastic and metal enclosures.

If a circular hole is required larger than a drill bit within my toolbox, I’ll consider buying a suitable drill – otherwise drill it at the largest under size and file out to size.

If a square or other odd shaped hole is required, after marking out the required shape, I’ll drill holes large enough to take a junior hacksaw blade at strategic locations and use the hacksaw blade only to make cuts between the drilled holes. I wrap one end the junior hacksaw blade in paper hand-towel material to form a crude handle. Once all the holes have been connected by a saw cut, the cut material will fall out. I then use a file to remove remaining material to achieve the precise marked cut-out shape.

Rather than using a junior hacksaw blade as outlined above, you could use a coping saw such as this:-

https://www.screwfix.com/p/forge-steel-coping-saw-6-165mm/8292c