"D" Hole Punch?

[PapaFoxtrot]

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.

 

[Psylocide]

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

 

[Stealthcruiser]

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

 

[PapaFoxtrot]

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

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

 

[Psylocide]

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

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?

 

[Stealthcruiser]

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".......

 

[alphaomega]

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

 

[PapaFoxtrot]

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

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...

 

[PapaFoxtrot]

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

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

 

[iijakii]

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:

 

[Psylocide]

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:

.


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

 

[Shockerengr]

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.

 

[TastyAdventure]

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

 

[PapaFoxtrot]

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

Oh! A wise guy, eh?