In the process of building toys/models out of brass and sheet metal, I occasionally run across the need for a small, square hole.

Holes in thin material are best punched. I have a Whitney punch that will make round holes from about 1/16 to 1/4 and it works great.

What I'd love to find is a Whitney-style punch that makes square holes in the same size range.

I'm aware of Greenlee punch/knockout tools but they're too big and WAY too expensive.

Any leads/ideas appreciated. Under $100 absolutely, under $50 preferred.

HSS lathe tool blank. Rotate square end against spinning spherical sharpening stone. You would end up with a square end with sharp corners to initially pierce the material.

I'm sure there are eisier ways. But this is my first thought.

Maybe these? If the metal is thin and soft enough they would probably work. For a few holes anyway. Probably wouldn't leave clean edges on the backside though.

https://www.amazon.com/Leather...ds=square+hole+punch

quote:

Originally posted by CaptainMike:
Maybe these? If the metal is thin and soft enough they would probably work. For a few holes anyway. Probably wouldn't leave clean edges on the backside though.

https://www.amazon.com/Leather...ds=square+hole+punch

Yeah, I looked at those. Pretty cheesy looking, I have my doubts they'd punch a hole in anything thicker than paper.

Great question. I'd probably end up making them, starting with round punches. A fine file, bench vise, and calipers.

How thick is the metal you are working with?

These may be good enough for brass.

http://www.leevalley.com/us/wo...?p=65380&cat=1,43456

quote:

Originally posted by sigmonkey:
https://www.ebay.com/itm/28334...m=&item=283344525272

Saw that. Bit out of my price range, but I may not have any other options.

Try looking here: https://www.zoro.com/?gclid=Cj...ALw_wcB&gclsrc=aw.ds

I've found punches here in the past. It's a great company with top notch CS.

Jim

You're doing relatively soft metal?

Broaching is your answer.

Make one. Knowing how much stuff you've got around your shop, this should be a piece of cake for you. Probably at Zero Cost.

Since the Karmanator is down, I can't embed this. Here's a link. Surely you can make a better square than this guy.

LINKY THINGY


BETTER LINKY THINGY

Or Google "square broach"
.

Might have to grind a flat or slight angle on the end.

https://www.amazon.com/Yakamoz...ble+square+bit&psc=1

quote:

Originally posted by CaptainMike:
Maybe these? If the metal is thin and soft enough they would probably work. For a few holes anyway. Probably wouldn't leave clean edges on the backside though.

https://www.amazon.com/Leather...ds=square+hole+punch

I'd guess they are quite soft.

quote:

Originally posted by OKCGene:
You're doing relatively soft metal?

Broaching is your answer.

Mostly brass, and thin brass at that.

A broach would sorta work, IF I had dies top and bottom to support the metal. Otherwise, it would tear rather than cut.

quote:

Originally posted by jhe888:

I'd guess they are quite soft.

Yeah, I'm pretty sure that's soft Chineseum. I'd bet good money the "edge" would fold over on the first tap of the hammer.

Be lucky to cut leather with that, much less metal.

@ OKCGene -

That guy in the second video is a freakin' genius! I've seen several of his videos.

If I'd started 50 years ago, I wouldn't live long enough to get to his level.

That said, I have a bit more finesse than the guy in the first video...

quote:

Originally posted by OKCGene:
... BETTER LINKY THINGY ...

I was going to post that, too. Clickspring is one of the most interesting channels on YouTube.

quote:

Originally posted by shiftyvtec:
HSS lathe tool blank. Rotate square end against spinning spherical sharpening stone. You would end up with a square end with sharp corners to initially pierce the material.

I'm sure there are eisier ways. But this is my first thought.

This was my first thought too.

Would these work? Not sure on the size though.
https://www.tool-rank.com/tool...e-holes-20100413655/

It just occurred to, how about a square drive bit? They come in various sizes.

quote:

Originally posted by mr.sig239:
Would these work? Not sure on the size though.
https://www.tool-rank.com/tool...e-holes-20100413655/

Hmmmmmmmmm. The smallest is 1/4" which would work for some stuff. Might have to get one just to try it out.