What's the right tool?

[ocean_jet]

I got this 1/4" steel plate that has these existing rectangular holes it it. Looks something like this.

The holes are about 1/2" by about an inch long. I want to carve out the red areas making the holes bigger.



I could use a hand file but I have a bunch to do and it would take a while.

I tried using a little Dremel grinding bit on a die grinder but I ate through the grinding stone pretty quick.

Is there some sort of cutting bit or cutting tool that could be used to cut that material out of there?

Thanks.

 

[jonzer12]

An die grinder or dremel will work but you want a machining bit not a grinding stone,
I have a very high quality bit for cases like this, I got it as a hand me down from an aircraft machine shop but I imagine it was very pricey to buy new.
Torch or plasma would work great followed by some clean up with a round file.
Air Chisle might be another option.

 

[WebDog]

Plasma would be the fastest...

 

[ocean_jet]

An die grinder or dremel will work but you want a machining bit not a grinding stone,

I guess I'll look into this. It's got to be cheaper than a plasma cutter.

 

[WebDog]

Send me a dimensioned drawing and I can cut one on the plasma table for you... Would be like $4 to ship usps.

 

[xcm]

i would use a rotary burr from grainger etc.... its basically a mix between a drill bit, and a file..... it doesnt drill holes, it 'corrects' holes. ive got em in my toolbag at work now after seeing them perform on a disc conversion...

only downside? the chips are MEAN. more like shards of steel than chips.

 

[knucklehead 61]

this is the right tool & it is in my garage. i can punch them for you if you want to ship them up.

 

[Monster Mopar]

I'd use a rotary carbide bit, just chuck it up in a die grinder and go at it. They're expensive for what they are but really handy and well worth having in the tool box

 

[old_man]

I would use a milling machine. Doesn't everybody have one in their garage?

 

[fyrfytr1717]

I'd use a rotary carbide bit, just chuck it up in a die grinder and go at it. They're expensive for what they are but really handy and well worth having in the tool box

I'll second this one. They chew away at metal pretty dang fast and come in a variety of shapes and sizes depending on what you're going to use them for.

 

[MOUNTAIN XJ]

X3 on the rotary carbide bit it gets the job done really well for a little dremel size tool!!!
And as long as you have a good grip on the dremel you can get fairly exact cuts

 

[2stix]

one tip when useing the rotary carbide bits is to allow the bit to do the job, dont force it. a good sharp bit will cut like wouldnt believe with just little pressure. firm, not forcefull is the key to quality cuts and tool life.

 

[kastein]

also remember the bit will want to 'walk' so be ready for that, it's easiest to let it 'climb' the material and it won't try to dig in and away from where you want it to go quite as much if you go that direction.

 

[knucklehead 61]

I would use a milling machine. Doesn't everybody have one in their garage?

i think so. here is mine...

as for the carbide rotary cutters, they will work, but you get no precision at all with them.

 

[ocean_jet]

Thanks everyone, and thanks for the offers to cut it for me.

I got a carbide rotary bit. Don't need much precision.