Hello everyone. I have a question about cutting sound holes in thin sheet metal.
I'm building a 4stringer with a nice 11"x8" or so metal box I want to cut a sound hole in the lid with out destroying it or cutting my hands up. So rather than just fire up my hole saw, I thought I'd better ask for help.
This is my first build using metal. I usually use wood.
Any advice, help, war stories etc. Welcome.
BlAck...aka Ron H
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I have only ever did wood through holes but..
I used a dremel with cutting head to mark an x to each corner of the square I needed then bent the metal inwards. This also created 4 'flaps' that I used to secure the box to the wood with screws.
I have used a nibbler a lot for sheet metal. Nibbler
They work well on thin sheet metal though I have also used them on 18 guage.
If you know an electrician, they probably have a set of knockout punches,,, same with an HVAC tech. Another option is to drill small holes in a pattern,, always use a piece of wood as a backer while drilling sheet metal, and have the metal clamped down.
I have to be honest I haven't built a metal guitar yet but I am getting ready to. that said I have been a millwright for several years and do a lot of metal work of all sorts. I'm also a blacksmith artist. I use A plasma cutter sometimes but It wouldn't work too well if you don't want to discolor the paint. I would drill a hole to work through and then use a die grinder to shape it or a dremel tool. A nibbler would work great too. These are some things that come to mind first. Good luck And have fun. Dave (aka Wascl)
Just a thought.. But can you get someone to shoot it with a hand gun? Instant cool holes.
I just want it to be clear that I LOVE this idea.
That's a great piece of work
Amazing!
The biggest problem drilling thin metal with a 118 deg drill tip is tear out, so make sure you drill through the tin and a backing board together, a good option for tin is a step drill, as it's less aggressive fluting is less likely to tear
What darryl said: Step Drill... unless you're looking for >1.25" or so...
Hole saw will work, but clamp the metal (securely) to a piece of wood, clamp the pair to your drill press base... if it were to catch, you could lose a finger... or worse...
The hole saw will leave a terrible edge, but that's what files are for.
Punches work great, but they're not cheap.
Thank you one and all I now have a general Idea how to proceed.
I really appreciate your replies.
Ron H
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