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Cutting holes in copper

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Peter Simpson 109/05/2021 18:56:44
206 forum posts
9 photos

I need to cut two 1inch diameter holes in 1/8th copper sheet. I was thinking of using a step drill up to 22 mm then using a boring head to complete the job. Is there a better way ?

Ian P09/05/2021 19:04:36
2552 forum posts
113 photos

'Better' depends on circumstances and what equipment is available.

Your step drill followed by boring sounds good. Fly press and punch would be another way.

Ian P

Martin Kyte09/05/2021 19:05:03
2635 forum posts
46 photos

Brad point drills work well in copper. Nothing wrong with the boring head idea.

regards Martin

Clive Brown 109/05/2021 19:34:07
745 forum posts
37 photos

Chain drilling and a half-round file

noel shelley09/05/2021 20:29:05
1009 forum posts
19 photos

3/4"Wedon shank 1"rotabroach. A 2MT holder in a drilling machine. You then can do holes from 11mm up to about 1 1/2" with ease. You do need slow speed though. Noel.

not done it yet09/05/2021 20:37:58
6514 forum posts
20 photos

To what precision? A tank cutter is likely a possible approach? I’ve got various q-max tank cutters. They are only rated to 2mm but i’ve used them on thicker stuff ... they don’t say whether hard or annealed copper

JA10/05/2021 09:01:13
1282 forum posts
79 photos

Although the copper may be a bit thick I would consider using a piercing saw with a thin blade (less metal to remove). You will break blades but that is to be expected. Finish off with a small half round, or round, file ideally one that has no been used on steel.

I have happily cut 1/8" thick brass with a piercing saw and made 1/32" thick copper gaskets using the above method.


bernard towers10/05/2021 09:33:50
390 forum posts
102 photos

What’s wrong with a 1 inch step drill?

noel shelley10/05/2021 09:37:31
1009 forum posts
19 photos

A sharp Q-max cutter would do it. The Deluxe version has a hollow hydraulic cylinder That develops about 5Ton pull - easy to use on the bigger sizes ! Where are you ? Noel.

Tim Stevens10/05/2021 17:45:05
1517 forum posts

I would use a piercing saw followed by a fine (fairly new) half-round file. Depending, of course on how critical the roundness is, as well as the measured diameter.

Cheers, Tim

Mark P.10/05/2021 18:20:36
623 forum posts
8 photos

How about clamping it between two pieces of plywood and using a hole saw?

Mark P.

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