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'[OT:] cutting D connector holes'
2004\02\04@134720 by John Pearson

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Is there an easy way to cut mounting holes for 9 pin D connector housings?

I have searched for punches, but cannot find any, probably because I don't know what they are called if such a thing exists.

I am cutting into 1/16" aluminum and plastic.

Thanks

John

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2004\02\04@140004 by Dave VanHorn

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At 10:52 AM 2/4/2004 -0800, John Pearson wrote:
>Is there an easy way to cut mounting holes for 9 pin D connector housings?
>I have searched for punches, but cannot find any, probably because I don't
>know what they are called if such a thing exists.
>I am cutting into 1/16" aluminum and plastic.

Greenlee makes D-Sub punches.
$200-ish IIRC.

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2004\02\04@140627 by Michael J. Pawlowsky

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One google search for DB9 Punch gave me this:

http://www.l-com.com/jump.jsp?lGen=detail&itemID=7452&itemType=PRODUCT&iProductID=7452

$$$$$$$$



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On 04/02/2004 at 10:52 AM John Pearson wrote:

{Quote hidden}

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2004\02\04@141252 by al smith

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Mouser carrries them as well.....$250 or so.  Expensive unless your doing
alot of panels.  Might call around to the local metal fab shops and see if
they have one, and what they would charge to punch for you


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2004\02\04@142708 by Rick C.

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As you can see, they are expensive, but that's the going price for good punches if you plan on punching for production work. If
you are wanting to punch a few holes for hobby projects, you can use a template to scribe out the "D" and the mounting holes,
drill the inside as close to the scribe marks and finish it off with small rat tail and flat files. The "D" doesn't have to be
perfect. The connector will hide a lot of slop if it ends up to be more of a rectangle rather than the tapered "D".

You'd think they would come up with a round hole mount connector for the Sub D's but I guess it's not worth the R&D effort and
limited manufacture of such.
Rick

John Pearson wrote:

{Quote hidden}

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2004\02\04@143531 by Wouter van Ooijen

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> can use a template to scribe out the "D" and the mounting holes,

I use the slot brackets of old PCs as templates.

Wouter van Ooijen

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2004\02\04@173133 by llile

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Wouter, I guess you are getting some use out of those old PCs.  To use
mine, I would have to haul them up by the chain and swab out the barnacles
(boatanchors)

-- Lawrence Lile





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> can use a template to scribe out the "D" and the mounting holes,

I use the slot brackets of old PCs as templates.

Wouter van Ooijen

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2004\02\05@122612 by ?q?Debbie=20Hynes?=

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--- Dave VanHorn <EraseMEdvanhornspamspamspamBeGoneCEDAR.NET> wrote: > At 10:52 AM 2/4/2004 -0800,
John Pearson wrote:
> >Is there an easy way to cut mounting holes for 9 pin D connector housings?

i do a drawing in cad (intellicad or sim) to make a template. print out the
whole panel layout, d-connectors with cutting outline + other drill holes etc,
on A4 trace paper, tape that over the aluminium or plastic whatever then use a
needle punch to delicately outline where the cuts have to be. then drill
*inside* the outlines and use needle files to trim. it's a LOTTA messing about
4 sure but there don't seem to be any cheapo punches around. :(
Debbie :)

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2004\02\05@124029 by Alan B. Pearce

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>> Is there an easy way to cut mounting holes for 9 pin D connector
housings?
>
>i do a drawing in cad (intellicad or sim) to make a template. print out the
>whole panel layout, d-connectors with cutting outline + other drill holes
etc,
>on A4 trace paper, tape that over the aluminium or plastic whatever then
use a
>needle punch to delicately outline where the cuts have to be. then drill
>*inside* the outlines and use needle files to trim. it's a LOTTA messing
about
>4 sure but there don't seem to be any cheapo punches around. :(

For this sort of thing it is probably worth having a small milling machine
(Dremel, Proxxon, Bohler etc) and hand winding the controls to mill an
outline made in a manner such as Debbie and others have suggested. Judging
by the UK price of the Proxxon machines, it would probably be possible to by
the milling machine for less than the US price of a single punch. Not only
that but you then end up with a universal machine capable of a lot more.

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2004\02\05@130715 by Robert Young

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> --- Dave VanHorn <spamBeGonedvanhornSTOPspamspamEraseMECEDAR.NET> wrote: > At 10:52 AM 2/4/2004 -0800,
> John Pearson wrote:
> > >Is there an easy way to cut mounting holes for 9 pin D connector
housings?
>

If you are in the US, Mouser has reasonably priced D-sub punches for about
$180 where you drill 3 holes or a Greenlee punch that only requires 1 hole
to be drilled (and is about $420).

I have the Deltron type and they work just fine on plastic, Al and mild
steel.  Broke one trying to modify a stainless-steel case once.  Pretty
impressive noise when it snapped.

Consider what your time is worth to you.  If you are doing things on your
own dime then fooling around with drills and Dremmels might be OK but with
the Deltron type I can have a hole punched in about 10 minutes or less
(assuming I can find my drill bits to make the pilot holes).  If you value
shop time as low as $30 you can pay for a punch after just a few uses versus
drilling and filing.

http://www.mouser.com/catalog/617/1179.pdf

You might be able to find the Deltron punches through other sources too.

Robert Young
KILLspamrwyoungspamBeGonespamieee.org

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2004\02\05@142426 by Alexander JJ Rice

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On Thu, 5 Feb 2004 12:06:02 -0600, Robert Young <@spam@rwyoung@spam@spamspam_OUTIEEE.ORG> wrote:

> with
> the Deltron type I can have a hole punched in about 10 minutes or less
> (assuming I can find my drill bits to make the pilot holes).  If you
> value
> shop time as low as $30 you can pay for a punch after just a few uses
> versus
> drilling and filing.

I can easily drill and file a hole in 10 minutes - as suggested you do a
quick autocad or whatver drawing - print it out on a sticky label or use
some spray mount, drill the centres of the holes and use a fret saw with a
fine blade to 'join the dots' a quick bit of neatening up with a file and
you're away. I have even used a power jigsaw/ scroll saw with a fine blade
to do the same thing so long as youre not trying to do it on stainless -
this is particularly good for large things like fan cut outs as it takes
longer to take the blade out and put it through one of the holes you have
drilled than on a hand saw. It owuld probaly be quicker with a milling
machine, but i don't have one sadly.

Regards

Alex

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2004\02\05@151540 by Robert Young

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{Quote hidden}

Draw, print, cut-out, locate, tape, drill (more than 3 holes), saw, file.  8
steps (7 the next time since you don't re-draw).

Locate (my punch has a template piece for locating the pilot holes), drill
(3 holes or single depending on punch), assemble punch, turn wrench.  4
steps.

I didn't account for assembling tools in either case since it would probably
be about the same number of tools or steps.

For simple shapes like holes, squares and rectangles a drill and file may be
quicker but to get a nice neat D-sub hole, but especially for inside
mounting a punch is pretty slick.  For outside mounting where the flange of
the connector covers any ugly maybe cutting and filing is OK.

On the other hand, I have access to some small machine shops that can do
custom steel and aluminum cases at reasonable rates.  For a personal project
I wouldn't use them but for client financed jobs it is well worth it to pay
somebody else to do the mechanical prep while I concentrate on circuits and
hardware.  Just gotta be sure to coordinate at the start so we don't end up
with a round hole and a square peg!

Rob

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