Sheet metal work?

[Slowhand Bob]

For those of you using metal liners, what are you using and are you still cutting them individually by hand?  I would like to know if anyone has taken the next step and stamping out the thin metal liners?  I have been getting my liner metal from a local shop but have not asked them about any production steps or if they do such.  I figure that if one has to shop it out on a small scale it just might add to much to the individual holster cost.  So far I have been lucky and have not sliced a hand yet with the hand cutting but I know its bound to happen if I do not find another way!

[tombogan03884]

Unless you are handling a large volume the cost may be prohibitive.
There are 2 types of "punching machines that can be used.
The first is the single stage which requires 1 punch, and one die precision ground to the exact dimensions of the piece you want. in that case the tooling can cost hundreds, if not thousands, of dollars.
The other method is with a turret style punch press using standardized tooling to cut the shapes out of a sheet of metal. this method while using much less expensive tooling will require you to purchase an entire blank of material for even one piece, it will also include the cost of writing a program since even on an old manual  machine a plan needs to be made as to which tools will be used in what positions to achieve the proper result.

[Timothy]

Laser cutting would be far more cost effective if you have a CAD file that the shop can import for the NC part.  It's what I've been doing for the last 16 years.  If they need to create the CAD and do the CAM part, you're looking at about 80 bucks an hour.  The shop time would be less than that in most areas of the country, figure 40-60 bucks an hour.

To cut a small piece of metal (I'm assuming it's pretty thin stuff) would literally take seconds.  A sheet of 304 SS would run the shop about $1.50 to 2 bucks a pound.  The laser cutting is minimal but you may need to buy a complete run to make it cost effective for them to bother. 

Give me a sq inch of the piece and I can give you an idea on how many you can fit on a standard sheet stock..

[MikeBjerum]

What volume and what gauge sheet metal?

If it is light enough, have you tried a roto tool following a template?

[Slowhand Bob]

Talking 20ga aluminium and yes I have considered something similar to your template suggestion BUT my thought was to use the pneumatic nibbler rather than a grinder.  I am planning to try converting some old screw style sheet metal hole punches to some sort of hydraulic press operation to speed that up slightly. 

[Sponsor]

[tombogan03884]

20 ga aluminum ? That's .022 .
The nibbler would be a much better choice, or even a good pair of shears.

[Timothy]

There are any number of deburing tools to take the knife edge of the aluminum after it's cut.  Check with Grainger, McMaster-Carr or even a good hardware store (and I'm not talking Home Depot).  They are quite handy to have around when you're working with sheet metal or plastic.

[MikeBjerum]

A RotoZip with an XB-MC1 bit. 

Sandwich the aluminum sheet between two templates (one mounted on a post mounted to your bench and the other on top of the aluminum), and run the tool around the template.  Back when I bought mine there were actually videos on how to do this with several materials.  This set up will handle 18 ga. steel, so it will walk right through 20 ga. aluminum.

I have one of these that I bought for drywalling, and I have found so many uses for it that I will never give it up.  This setup will be much faster than a nibbler or shears, and far cheaper than tooling up a punch press.

[Slowhand Bob]

How durable are those bits?  Best I remember they are pretty pricey.

[MikeBjerum]

They are tough as long as you don't force them.  I sheetrocked an entire house with one bit - outlets, switches, recessed lights, and several window and door openings.  I have run a wood cutting one through an electrical conduit by accident, and it still cut wood for a while.  The metal cutting bit should stand up to aluminum for quite a while.