"Q" wrote in message
k...
I need to make some square ( approx. 50*100 mm ) and round ( approx. 75mm
diameter ) holes in either 2 mm steel or 3 mm aluminum sheet..

I can cut the round holes using a holesaw ( bimetal body, carbide tipped )
in the drillpress, but how do I cut the square holes with a good result?

I have a drillpress ( cheap one ), but I am willing to invest some money (
not a fortune though ) in the proper tools if needed.. A CNC mill would be
nice, but not quite within the budget .-)

Any suggestions will be appreciated

/peter ( another one of those weird scandinavians )

Peter,
For the square holes, while it would be a PITA, you can make a layout,
drill the corners (larger diameter than a blade is wide), then cut the
entire square out with an electric saber saw (jig saw?). Certainly not the
best way to go, but it does work. Be certain to match the blade to the
job at hand if this becomes your choice. Drilling the corners allows for
the blade to make the 90 degree turn, if that isn't obvious to you. This
would be relatively easy with aluminum, not so great in steel.

I agree, if you can get a Greenlee punch that would work, that's the best of
all worlds, even if you have access to a mill. The only thing better would
be a large punch in a proper press. A mill would not address the sharp
corner I assume you desire. .

Harold