On Sat, 09 Apr 2016 20:04:14 -0500, "Lloyd E. Sponenburgh"
lloydspinsidemindspring.com wrote:

On Saturday, April 9, 2016 at 4:18:19 PM UTC-7, John Doe wrote:
I need to cut a 1/2" square through 1/4" aluminum. It doesn't have to
be centered, but the dimensions of the hole need to be correct.
---------------

Your subject said "with NO TOOLS". I'm not sure how you can justify
using even a drill bit with the 'no tools' restriction.

Answer: Rent a machinist. No can do otherwise.


I'd suggest that with some sand, some durable fingernails, and months of
time, you might be able to erode a _somewhat_squarISH_ hole in a thin
sheet of aluminum.

g I'd use my ShopFox Mortising Machine and end up with a perfectly
square 1/2" hole. Many aluminum alloys aren't much tougher than wood.



NO tools? Really?

The troll gotcha, did he?

--
If you want to make your dreams come true,
the first thing you have to do is wake up!
--anon