Enclosure making essentials (metalworking, holepunching, etc.)

[Enzo]

Add me to the list of step drill owners. I have a wide one and a narrow one. I also still have a pair of the older version that I call a cone drill. Same idea as the step drill, but no steps. You drill down as wide as you want the hole.

I have Greenlee punches for chassis holes like for tube sockets. I couldn't justify the cost for a square punch, but a couple starter holes and a nibbler makes a fine rectangle hole for an IEC connector.

And I often reach for the Dremel and some sort of grinder bit or cutoff wheel for some basic metal shaping and hole adjustment

[jrfrond]

I have to tell you, I CANNOT say enough about the Marson Thread Setter. Here is a place that sells the kit:

http://www.rustrepair.com/STEPVAN_PA...-MI.MOU-M39202

One of the best things with this tool is that you can add threaded flush inserts for transformers, tube sockets, circuit boards (as standoffs) and as mentioned, chassis retaining screws. You won't have to mess with getting your washers and nuts aligned with the screws, dropping them into the chassis, cursing, throwing things, etc.

You can also select the insert material, i.e. aluminum or steel. You need to practice a couple of times to get the hang of it, but once you do, you'll be hooked, or shall I say, SCREWED!