"D" Hole Punch?

I picked up some 3 pin panel connectors for my temp probe cables. They're made for a D shaped hole to keep them from turning when you unscrew the female end. I found a punch on McMaster, but at $230 - that's a nonstarter.

I'm curious if any one has suggestions on cutting a D shaped hole? I'm leaning toward a drop of JB Weld on the flat side of the connector in a round hole. Maybe file a couple shallow v-grooves in the side for extra bite.

 

How good are you with a dremel tool? Might be an option.

 

Trace it out, "chain drill" out the excess, and finish with a Dremel or a file.

 

Thought about that, but the panel is 0.1" stainless. I'm guessing that wouldn't be a fun job.

 

I was thinking more along the lines of doing a triangle with the cutting wheel, then get in there with a cone bit and round out the two angles.

Edit: Stainless might be tough going. Got a scrap of it lying around?

 

Ya' mean like a "Unibit" type?

That would probably try to walk on you, and turn the triangle into a "round".......

 

Screw it! (Pun intended)
Just drill a round hole and tighten the sucker real good.

 

Soon - I'll be using a bimetal hole saw to cut openings for the element outlets. Three 2" circles to play with.

Yeh - the idea of using a dremel on SS just doesn't appeal to me...

 

It'd be just like me to overthink a 12mm hole...

 

I hated those panel mounts without much of a flange at all. Using one like this makes it so much easier to drill and secure:

 

I don't think it would really... the stone is smaller than the hole, round out the one angle, then do the same on the other. You'd only be working 1 angle at a time and leaving the straight side of the sideways triangle alone.

See my very detailed technical drawing.




I would think you would be able to get it done with a cutting wheel and this:

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But haven't cut stainless a whole hell of a lot with a dremel.

 

Round holes work fine for those

the flat spot is to help keep the connector indexed absolutely, but they don't tend to rotate much once installed.

 

Happy to say I've never been punched in the d hole

 

Oh! A wise guy, eh?