I think im gonna use the nibbler tool to make square holes for all my switches, but do all of them come in the same size how about ones which cut thinner strips? Anyone know if they exist, or where to get them.

Thanks

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That looks a lot like a modern version of the Adel Tool Co. (Chicago) nibbler that I have that takes a 1/8-inch swath out of the metal. It is a bit big and takes a danged 1/2-inch hole to get it started in the middle of a piece of sheet metal.

For the square holes required by slide switches, I use one of two methods. One is to put the sheet metal over some hard wood such as oak and use a 1/4-inch or smaller wood chisel and a hammer to make the square hole. The other is to use a drill to start an undersized round hole and a Dremel rotary grinder to work out the bulk of it and small mill files to sharpen up the corners. That's why I like toggle switches with their round 1/4-inch or 15/32-inch holes. Trouble is, slide switches are so darned cheap and I have hundreds of them! Hate to waste the things.

Dean

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Dean Huster, Electronics Curmudgeon
Contributing Editor emeritus, "Q & A", of the former "Poptronics" magazine (formerly "Popular Electronics" and "Electronics Now" magazines).

R.I.P.

 

I found this tool much more useful than a nibbler to make small odd shaped openings in project boxes:
http://www.axminster.co.uk/product.asp?pf_id=21142

It works fast, like a round saw blade, in plastic or die cast boxes. It seems to last forever - mine is more than 10 years old - and the cut only needs a light dressing with a square file to get those nice corners. Best of all is it starts in a 1/8" hole, drill a hole at each corner and "saw" out the remaining material. Cutouts for 'D' type connectors? no problem
Klaus

 

Like Dean, I use a Dremel tool but use the tiny cutoff wheels to cut the straight sides - and a file to clean up the corners. Safety glasses are a must!!

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stevez