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Comment by Charles Small on January 31, 2020 at 9:01am

Professionals, who can write them off as tools of the trade, have power nibblers. But a simple hand-squeezed nibbler - although limited in the thickness of sheet metal it can accommodate - can make some fairly complex and precise holes in sheet metal as well as trim sheet metal to shape. Take your time. Practice on scrap. Be prepared to do some filing after using a nibbler.

Comment by Jim Morris on May 2, 2017 at 11:21pm

Thanks for the info Dave.

Comment by Dave Lynas on May 2, 2017 at 10:52pm

To do big holes in metal, I drill a series of small holes in a row around the perimeter as close as possible (almost touching). Then I use a small chisel to cut the metal between holes. This removes the center disc. The jagged edge is then sanded into smooth with a Dremmel sanding drum ( the larger one ). It's fussy, but works fine. The diamond embedded wheel for Dremmel works too. It will cut a slight curve in thinnish aluminum or stainless. It is quicker than the hundred hole method.

Comment by Jim Morris on May 2, 2017 at 1:58pm

Thanks for the info Wade. Making holes in wood I can do pretty well but metal of any kind is a challenge for me. I thought maybe you had a secret for making perfect holes in metal!

Comment by Wade on May 2, 2017 at 1:38pm

Thanks Dave! I will post some pics in natural light where it will look better. I was close to the deadline for this build so I had to take indoor pictures.

Comment by Wade on May 2, 2017 at 1:35pm

Jim, for wooden cigar boxes I inset the lid using a roto zip tool. The antique aluminum cake pan was much thicker than the new ones, so I just surface mounted it to avoid aluminum shrapnel in the shop! I was thinking of drilling a 2" hole into the body under the lid hoping to move more air into the body, but that's just my theory. Don't know if it would affect sound/volume.

Comment by Dave Lynas on May 2, 2017 at 4:43am

I'm glad you're back too. It's my eye candy!

Comment by Jim Morris on May 2, 2017 at 12:43am

Nicely done! Is the paint lid set in a hole or sitting directly on the cake pan?

Comment by Wade on May 1, 2017 at 11:28pm

Thank you Jerry, Pick and Dave. Been away from building for a few months - it's good to be back.

Comment by Dave Lynas on May 1, 2017 at 11:05pm

Wow Wade. The best at the finish line! Gorgeous!

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