Home Tweakers' Asylum

Tweaks for systems, rooms and Do It Yourself (DIY) help. FAQ.

Re: Chassis punch for duplex AC receptacles?

Greenlee makes a "double D" chassis punch that will punch the hole you need. Take a deep breath and then click the link below to see the price :-(

When I've had to do it, I simply take a steel duplex outlet cover and turn it upside down on the panel and trace the outline of both double D holes onto the chassis. After that, take a 1/8-inch drill and drill closely spaced holes around the periphery of the outline such that the outer diameter of the drill bit just touches the line. Once you've drilled all the way around, cut out the inside of the double D and then smooth the edges with a carbide bit in a die grinder.

Are the holes perfect? No but they cost a lot less than that chassis punch AND a little black magic marker on the cut edges goes a long way towards hiding any imprefection. It takes about an hour to do two holes this way.



Bill's Audio Cave


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