Cutting holes in copper

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 ?

'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

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

regards Martin

Chain drilling and a half-round file

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.

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

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.

JA

What’s wrong with a 1 inch step drill?

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.

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

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

Mark P.