Tool to create professional IEC chassis cut-out...


Hello,

I am curious if anyone knows a source for a tool to create IEC block (for 15 amp detachable power cord) cut-out hole in metal chassis? I know many folks just use a dremmel motor tool to "nibble" a hole, but I'm looking for something that is purpose-designed and will provide professional-looking results.

As an example, such a tool would be invaluable for adding high-quality detachable power cord to Dyna gear, as well as other vintage tube equipment which is popular for rebuild / upgrade DIY projects. Any help will be greatly appreciated!!
gthrush1
When the chassis for your component is made, ALL of the holes are punched on a press before the material is bent to shape. Even a very small punch press is a bit much for the DIYer (not even mentioning the cost to make the punch/die in the shape of an IEC jack).

As an alternative, you may consider creating a jig that will guide a narrow high speed router bit around the shape you desire to cut out. This is an incredibly messy way to do the job, requiring the chassis to be empty to avoid contamination from the metal shavings the router will produce.

Last and probably most practical is to have a small local machine shop use an end mill to cut the shape. If done at low speed, this could (depending on the chassis material) be the cleanest method. If they do it on a computer controlled mill, you'll pay for some programming the first time, but should get away cheaper for subsequent jobs. As always, the more parts you do at once, the more economical it will be.
Be very careful, I added IEC sockets on a pair of monoblocks I had, well they’re in there but a little unsightly. That being said I would recommend having it professionally done if at all possible, my screw up has inhibited the sale of my amps(fortunately they are cheap enough it isn’t a big deal), almost a shame! Good luck with it.
Tim
I recall seeing just such a chassis punch tool available from Parts Express. http://www.parts-express.com/