Gentlemen, Hope you are fine wherever you may be.
I have a job which came my way which calls for making 2"x2" square holes in 3/4 inch aluminum plate. I am a construction worker, carpenter, with access to a heavy mill-drill machine and a small home shop size band saw. I have to make24 of these square holes in separate 5" x 6" x 3/4" sections. The tolerances are not tight. + or - .01 inches is ok.
My question is what is the best way to do this? From what I can see there are three choices.
- Layout the square, drill a 5/8 hole, put a hacksaw blade through and start hacking away. Finish off using an end mill. Of course I might need a new set of arms when I'm done. i need a new brain already!
- Due the same but weld the bandsaw blade through each plate and cut using the band saw before finishing with the mill.
- Drill out a square shape formed by a series of holes using a 1/4" drill bit and finishing with the mill.
My 3 ideas might suggest to you that I have little experience with machining metal. And that would be quite true. So I would appreciate your suggestions.