best way to cut holes in metal lensboards?

darinwc · Sep 11, 2013

Hey there!
I have a small drill press.
What is the best way to cut holes in metal lensboards?
Can I use a hole-saw or do I need large bits?

THX.

cliveh · Sep 11, 2013

Laser.

Tom1956 · Sep 11, 2013

Take my word for it, in the friendliest possible terms. If you have to ask that, you are about to make a mess of the job. This doesn't sound like it's going to turn out well at all. Regards.

shutterfinger · Sep 11, 2013

Holes 1 inch or less- drill bits.
Holes over 1 inch- hole saw for metal only.
Clamp the work piece firmly!

AgX · Sep 11, 2013

There are also tools consisting of a central drill with an adjustable arm and a turning tool at the end.

rjbuzzclick · Sep 11, 2013

I have used Greenlee punches on the thin metal Speed Graphic boards.

George Nova Scotia · Sep 11, 2013

I think AgX is referring to this type of bit: http://www.leevalley.com/en/Wood/page.aspx?p=32275&cat=1,180,42316&ap=1 With careful use they can be used for soft metals. Get the best you can find and clamp everything down. Slow speed - can your drill press run at 300-500 rpm? If anything is off center you'll get a messy hole. Don't force it, slow is better. I'd guess a carefully set up metal lathe would be the option of choice.

Ian Grant · Sep 11, 2013

I just use a hole cutter on a drill, and/or acurved file, it's a quick job.

Ian

eclarke · Sep 11, 2013

CNC Mill

Fotoguy20d · Sep 11, 2013

I use one of these on a 10" Craftsman Press. Clamp everything down nice and tight, take it slow, and it works just fine. Afterwards, I clean the edge with a Dremel. I need to cut a Graflex board this weekend - I can take a shot of the setup if it'll help, but there's really not much to it.

Measure twice, cut once!

Dan

Gerald C Koch · Sep 11, 2013

Use a chassis punch they are designed to make circular holes for components on an electrical chassis. They make a very neat hole which does not usually required any further work.[

http://www.amazon.com/s/?ie=UTF8&ke...=aps&hvadid=1692479805&ref=pd_sl_40pbk94nge_e

Jeff Kubach · Sep 11, 2013

Practice on some scrap metal first.

Jeff

L Gebhardt · Sep 11, 2013

I've used a hole saw on linhof style boards with good results. The biggest was for a 12" Commercial Ektar which I think is an Ilex #4. I then tapped some holes for screws to mount the flange. With care it can be done on a small drill press. As others have said you must clamp things down well. I also used some cutting oil in a spray can.

bdial · Sep 11, 2013

Hole saws work well. I have also used woodworking Forstner bits, they work well, and make very clean holes, but you need to use a lubricant and a VERY slow feed, with the work peice held very securely.
With something thin like a Graphic board I'd sandwich it between two pieces of wood.

tkamiya · Sep 11, 2013

darinwc said:
Hey there!
I have a small drill press.
What is the best way to cut holes in metal lensboards?
Can I use a hole-saw or do I need large bits?

THX.

I'm guessing the hole will be something like 35mm to 50mm in diameter? Here's how I used to do it with simplest equipment.

Take a compus and draw a circle in the exact diameter I need.
Draw another circle (concentric) that is smaller. The size of this hole will depend on the drill bit you use.
Drill a bunch of holes all around the circumference of this smaller hole. I used to use 3mm bits.
Make sure, the outer edge of the holes are about 0.5 to 1mm inside of the outer (original) circle.
Then use a diagonal clipper or a small saw and connect the holes, so the disk can be removed.
Use a half round file to smooth it out to the diameter of the outer (original) circle.

It's not that much of work, if you are talking about relatively thin aluminum material.

adelorenzo · Sep 12, 2013

It's not that complicated. I use a hole saw (regular one made for wood, not even one made for metal) to cut mine and a half-round file to clean it up. I clamp the board to a piece of scrap 2x4.

NormanV · Sep 12, 2013

Just to add another choice, you could mark the circle, drill a small hole near to the inside edge of the circle and then cut around it using a metal cutting blade in a fretsaw/coping saw/piercing saw. I would be concerned about distorting the panel if you used a chassis punch as suggested.

Ashutterbug · Sep 12, 2013

Use a hole saw, it works great. Clamp it down well and use your slowest speed on the drill press. Feed the cutter slowly into the lens board.

John Koehrer · Sep 12, 2013

Ashutterbug said:
Use a hole saw, it works great. Clamp it down well and use your slowest speed on the drill press. Feed the cutter slowly into the lens board.

Hole saws for sure. Circle cutters have the extra height and diameter that need to be watched for. the board has tio be VERY secure. Well....so can hole saws, it's pretty exciting when the saw catches and spins the board especially if flesh is involved.

GRHazelton · Sep 12, 2013

Avoid blood and gore!

For the sake of your fingers and unless you enjoy the sight of your own blood, if you're drilling or hole cutting in sheet metal, put the workpiece in a vise or clamp it securely . As the drill bit breaks though its likely to snag the work piece and twirl it around, nicely butchering your hand. The chassis punches mentioned earlier are great things, but the ones I've used require a hole drilled in the center of the work piece, so still be careful.

E. von Hoegh · Sep 12, 2013

The best way? A lathe with a four-jaw chuck and a trepanning cutter. If you don't have that, there are second-best (and third, and fourth...) ways as outlined in this thread, they'll all work with care and patience. The advice to clamp the board firmly when using a drill press is advice you will ignore exactly once. With luck you won't lose a finger.

fotch · Sep 13, 2013

I would use my Sherline Mill, drilling a small center whole so i could then rotate the board with geared table (forget what it is called) and cutting the hole as it rotates.

Jon Goodman · Sep 13, 2013

You could use a .410 shotgun. Just attach the lensboard to a piece of wood and stand a few inches away from it when you fire the gun. Hole too small? Back up and try again. Hole too large? Get some duct tape and chewing gum to plug up the holes. Good luck.
Jon

Terry Christian · Sep 13, 2013

Jon, professionals don't use chewing gum to fill in spaces caused by grievous negligence!

That's what spray foam sealant is for.

paul ron · Sep 13, 2013

what ever you want to use.. hole saw or drill.. draw the circle accurately with a compass, cut your hole undersized by 1/16" or more, then file it to the finished line.

And yes.. clamp your work securely.. it saves alot of agaony as well as makes a better finished job.. ask us how we know?

neat n clean.. no fuss no muss!

best way to cut holes in metal lensboards?

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