Cutting Irregular holes in 2mm Checker-plate

[zuffen]

I need to cut 10 holes in 2mm steel checker-plate.

The shape is like an elngated letter "D" about 75-80mm square.

I figure I can cut the curved bit with a hole saw but the straight sections are too small for an angle grinder (my favourite weapon) and I'm not sure how a jig saw would handle the steel.

I know I could sit there for hours drilling a series of holes then joing them up and filing but I'm no masochist!

Perhaps I should just buy a plasma cutter?

Any suggestions.

[RustyArc]

You could blast the area out with a stick welder on high amps then clean up the edge?

[BRADFORD]

Jig saw should handle that, just make sure you have good quality blades

[Yonnee]

Plasma!

You know you want to!!

[zuffen]

I do but my wife doesn't and I guess that means I don't!

Plus I would need a bigger compressor if I went plasma.

I think the hole saw and a jig saw to finish off is the best solution.

[specialist]

I second the jigsaw, just get metal cutting blades and slow the blade speed a little if you have variable speed.

[Karl Robbers]

I would go with the jig saw too, however, don't discount a grinder with 1mm thick cutting discs. Used wisely they would achieve your goal, (assuming that it's not a 9' grinder we are talking about). In fact you may well find that a jig saw will handle your task without the use of a holesaw.
Use a fine tooth metal blade and possibly some type of cutting lubricant and keep the blade speed down while firmly supporting the work so it desn't chatter too much.

[Ben Dono]

I use a lot of the 1mm thick cut off disks in my small grinder and I always keep the small wheels that are worn away for situations like this. The small wheel fits in a much smaller area! Flexcut ( I think it's flex cut) are the best but makita are flooding the market with them too. They are just a bit thicker at 1.2mm. have not tried them yet but I bought some last week to give them a go.

[zuffen]

Good idea using the small "left over" discs.

I have a heap of them as I use around 10 a week.

Hopefully I'll get it all sorted and start cutting later this week.

[monkeyrelish]

I need to cut 10 holes in 2mm steel checker-plate.

The shape is like an elngated letter "D" about 75-80mm square.

Hi zuffen, you may have already found a solution to your problem. If not maybe have a look at a hydraulic hole punch similar to the one in the link below.

15 TON HYDRAULIC METAL HOLE PUNCH KIT WITH ROUND AND SQUARE DIES 22.5-76mm | eBay

A few guys on one of the local hot rod forums I frequent have a lot of success with these in their fabrication work. You can buy the kits with round dies only for under $100 but I think at least one square die would come in very handy. Or if you know anyone with a lathe they may be able to turn up a die specific for your needs.

Cheers

[zuffen]

I ended up not cutting the holes.

I figured out how to tie the car down without the tie downs in the floor.

The car should register in the next 10 days so I can now sell the trailer as I don't need a tandem trailer for the stuff I usually drag around.

Are you on Ozrodders?

[monkeyrelish]

I ended up not cutting the holes.

Are you on Ozrodders?

Yeah that's one of the many forums I am addicted to. I read through your build a few times over the last year and the van has turned out bloody nice. Good work

[zuffen]

Wednesday is rego day.

Once registered I'll post a photo here (if the site allows me as it times out when I post) so otheres know what we're on about.