"Larry Jaques" wrote in message
...
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.

My high school shop teacher was a retired Swedish cabinet maker who
taught us the traditional skills, like how to hone a wood plane blade
or joint, file and set the teeth on a handsaw. Before turning us loose
on the power tools he required us to plane a block of wood square
enough to pass the sliver of light test with a try square.

While I sure do appreciate power tools I don't have to depend on them.
One of Friday's projects was filing angled slots for Tie-Wraps to
attach a large capacitor to an aluminum panel.

--jsw