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

Slingshot,

The alternative I've chosen is to select a powercable I like, drill the hole slightly larger and hardwire the sucker in. Best connection you can have and the only downside of course is not being able to quickly change out and compare future cables.

Greenlee Tool Co. makes an entire series of "Radio Chassis Punches" both round and rectangular. Sorry I don't know their website. If you know the openning size you need you can check with larger industrial electronics suppliers. Greenlee punches are popular for their ease of use and durability with both electronics hobbyists and electricans.

I just put an IEC socket on my satellite receiver using a dremel. I used a slide in IEC socket and when it popped in none of my cuts were visible and other than the fact that I cut through some wording it looked just like it was meant to be there. If you're really worried about it you can always file the cut area to make it smooth. leo.

Why not hardwire an outboard socket in to the terminations inside the chassis, and not punch the chassis plate at all?

good course of action: use the IEC and a pen to trace the hole in advance. then use a drill w/ a VERY small bit to make a series of holes just inside the trace (as the IEC, if mounting from outside-in, will have a lip to cover everything). should be 20-30 holes. why so many? cause w/ a small bit the distance b/w holes can be very small, and b/c you cannot make a big mess w/ a small bit.
after all holes drilled, use a nibbler or sharp wire cutter to finish cutting out the hole. insert IEC, then drill the mounting holes for the IEC after its in place
rhyno