Like many homebrewers, I cut my panel holes with a jigsaw, and finish
them with files. The advantage: Essentially any shape and size is
possible. Disadvantage: It takes a bit of practice to get nice, clean,
good-looking results.
It's a good idea to use panels of a reasonable thickness. There is just
no point in making them as thick as an armor plate! For small boxes I
use 1mm aluminium sheet, for bigger ones slightly thicker sheet, and
only for the biggest boxes holding the heaviest sort of components I use
3mm thick aluminium.
On the other hand, I have used the jigsaw+file method even in 8mm thick
steel, when building machinery! That takes some patience, though, and
might wear out one jigsaw blade per hole. But that's still cheaper than
having the work done by others.
Shop safety is not to be taken lightly. It pays to think in advance what
can go wrong, and prepare for it. For example, a jigsaw blade can
shatter and fly away, and small metal chips will certainly fly around.
So, eye protection is a good idea. I also use ear defenders, as I like
listening to music and don't want to go deaf. And un-deburred metal
edges can cut fingers... but that's pretty obvious! Come on, we are no
kindergarten anymore! ;-)
Manfred
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Visit my hobby homepage!
http://ludens.cl
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