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A simple way to drill a square hole in a metal

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Any hole, if it is made using a drill, has a round shape and in order to make it square, you need to work well with some filing tool. Let us consider how to drill a square hole in metal with minimal use of a file using the example of manufacturing a convenient and reliable tap wrench.
square hole in metal

In order to make a wrench with a square hole for a tap having a side of 10 mm, you will need:
1. Metal rectangular bar-workpiece 13 mm thick.
2. Electric drill.
3. Kerner.
4. Center drill.
5. Drills for drilling metal with a diameter of 4mm and 9mm.
6. Any coolant.
7. A small trihedral file.
harvesting

The manufacture of the winch is as follows:
1. A paper is made of paper with a side of 6 mm, mark the center on it and glue it on the workpiece at the place of drilling the hole.
hole marking

2. Lay the blank on a suitable anvil and mark the tops and the center of the glued square on it with a core.
core marks

When the paper is removed from the surface of the workpiece, five corrupted marks remain on it.
core marks

3. Fix the workpiece with clamps on the surface of the workbench, having previously placed a wooden plank under it.
clamp fixation

4. A center drill drills all five holes marked on the workpiece.
centering drill

core drill 1

5. Finally drill with a drill having a diameter of 4 mm, four holes in the vertices of the square,
4mm drill

not forgetting to cool them with a small amount of coolant from time to time.
drill cooling

6. Reducing the rotational speed of the drill, a 9 mm diameter drill will finally drill the last, fifth hole located in the center of the square, again without forgetting to cool it from time to time.
9mm drill

9mm hole

7. Disassemble the design of the clamps. The result is a billet with a drilled square hole.
uneven hole

However, the edges of the hole are uneven and the tail of the tap does not “fit” into it.
tap does not fit

8. In order for the shank of the tap to enter the hole completely, its edges are additionally treated with a file.It is more convenient to do this, of course, holding the workpiece in a vice, and all the work takes no more than 15-20 minutes.
file hole processing

After file processing, the square hole in the workpiece becomes smooth, accurate, and the tail of the tap goes into it completely.
square hole in metal

crank

This method of drilling a square hole in a metal billet reduces labor costs when processing its edges to a minimum. And the resulting collar will, when used, hold the tap shank securely and firmly. With careful storage, several generations of craftsmen will be able to use it.

Explanatory video on drilling a square hole in a metal workpiece.
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20 comments
0
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Google with Yandex to help you.;)
Guest Valery 0
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Your comment about Watts drill is good, but where can I buy it in our country, or at least in Minsk?
+1
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Small holes should be filed with a flat file, not a file. In addition, it is "monkey labor". In a hardware store or a flea market, for a penny, you buy a factory-made universal wrench. In it, the sides of the rectangular hole diverge under any rectangular shank, if not mistaken - up to 10 mm. Any skilled person has the necessary tools and accessories, including wrenches, swords, lehrs and so on. Anyone who does not have them will not be able to make a winch on their own, and why does he need it? Why write such nonsense. Tips should be practical.
+1
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Sometimes it does not allow the absence of the very normal collar with sliding jaws!))))
Although, seriously, if I had the rest of the tool, I would have made it sliding. Its easier to do ..
If already (and suddenly!) There is no tap, it would be possible to pass through the bolts through and tighten with nuts ...
And the rest of the tool is the same as for the manufacture of this ..
0
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And to take a normal knob with sliding jaws, the simplicity of action does not allow?
0
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And you can cast steel parts immediately with holes! ))))
I mean, that ... It’s very good that you have a piercing machine and a supply of copper electrodes in your garage or basement ... But most home masters have a maximum of turning and drilling machines ... And are content with that they drill a round one, and then "squash" it with a suitable mandrel ...
..Well, or like that ....
0
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You can burn a square hole on a piercing machine with a copper electrode, having previously determined the parameters in CAD AUTOCAD or any other Saprov program, for example, SOLID. )
+2
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Well, yes ... I agree.
... I somehow "superficially", just looked ... Without thinking ...
+2
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In this case - of course, made, but Victor Erofeev writes "a square hole can be made, but you can’t drill it," that is, its text clearly indicates a general case, and not specifically on this method. If he talked about the method described above, he would write "the author made a square hole, not drilled."
Maybe, Victor Erofeev I just can’t formulate my thoughts, but I answer what is written, and not what he thought, but did not write. )))
0
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Quote: Ivan_Pokhmelev
Your personal ignorance of the existence of the Watts drill does not give reason to make such loud statements. Of course, you can say that it’s not quite a square, but with practical accuracy it’s still a square. ;)

But, as if IN THIS CASE, we are not talking about “drilling” a square hole. Here it was "made", or "done" ....
0
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By the way, this phrase also cut me a rumor .... That's why I mentioned here about square drills!))))
+2
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Your personal ignorance of the existence of the Watts drill does not give reason to make such loud statements. Of course, you can say that it’s not quite a square, but with practical accuracy it’s still a square. ;)
+1
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Blue bullshit. A square hole can be made, but you can’t drill it.
+6
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drill diameter should be equal the thickness of the square)
??? smile
+7
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I do something completely different. I take the square of the right size: I sharpen the nose slightly under the cone so that it fits easily into the hole (of course, you must first drill and of course the diameter of the drill should be equal to the thickness of the square), I heat the drilled workpiece, insert the "square" with a cone into the hole, of course, that's all put on such an emphasis that the square and not the cone went right through the bottom of the workpiece after a couple of times with a hammer from the top, that's all. Let it cool and the magnificent square hole is ready, by the way, without a file. Ask what to warm, but with anything, think! I used this method in the distant 60s to make holes in the metal with a simple nail! I didn’t have drills and drills then. And when I started to work and first saw how my “knoll” in the factory for a tap was making such a collar (as the author described), I realized that he got the position of a knoll early, I took it in Tihari and made a collar in 5 minutes in such a way as I did described above, and my "hillock" was tearing it with needle files for another hour and a half.
+8
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That's right - AT SCHOOL!
You were lucky with the Trudovik, and we grind hammers from iron bars with bald files! I still wonder how this did not instill hatred of plumbing. smile
+24
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Well, why should it be so right away ... I, too, at one time was amazed at how little the current generation knows about such "obshchuzhskih" things like the initial level of locksmith, lathe, and more ...
And then I thought ... That's where and when I myself learned about the fact that there are scrippers, that the holes are punching? ... Where did I learn to cut something choked in a vice with a chisel? Where was the caliper held for the first time? ...
That's right - AT SCHOOL!
And now, as far as I know, far from all schools have locksmith and carpentry workshops ... And they have no "work" for 2 hours a week, they don’t!
How do they know what scriber is ??? ...
(Recently, one thirty year old man was laughing at the word “spindle” I uttered ... He had no idea what it was ... Thought it was a funny comic curse.))))
So, not for Dumb, but for ... "greenhouse", most likely, such tips are needed ...
+3
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Tip for the most stupid. It is obvious. And a new word in plumbing is a paper template. But do we not know how to use the scriber and the ruler? Why centering drill? Kerner is enough. And something in the photo there is no vise. Not even a workbench. Oh, woe, master.
+9
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Well this is unlikely, normal craftsmen prefer a normal tool! smile

..square drills, for example ... boss
+9
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Of paper make a square with a side of 6mm
And we do not know how to use a caliper?
With careful storage, several generations will be able to use it. masters
Well this is unlikely, normal craftsmen prefer a normal tool! smile

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