Jim Reed wrote:
I am in the midst of fixing some farm machinery with new sheetmetal. The
metal I am using is 14 gauge, and the proximity to moving parts requires
carriage head bolts. The previous metal used 1/4" carriage head bolts, and
I would like to do the same. I don't have any idea how to create the square
holes. Each piece of metal is roughly 3 feet by 2 feet, and the holes will
be within 2 inches of one side of the metal.

Any help would be appreciated.

How many, to what tolerance? What's the budget like?

1) Prick punch, center punch, pilot drill then 17/64 drill. Create
corners with 3 corner file.

2) CNC Plasma torch

3) Water jet

4) Laser

5) Plunge EDM

6) Machine and harden a 0.27" square punch and matching die shoe. Load into your
arbor press and pop them out. Use lubricant and wear eye protection.

7) Drill and square broach

--Winston