re:7 square holes

Brian wrote:
Ok I've seen 4 ways to machine a square hole
1] the swing the B'Port head trick we talked about last month
2] broach a]thru hole broaching
b]wobble broach for blind holes
3] shaper or the shaper/key cutter attachment on the back of a B'Port
4]that polygon drilling attachment that uses a 3flute drill and
forces it to walk into the corners
5,6,7]???

Brian,

Thank you for your continued efforts on my behalf...

1) Drill and file. This was the longest part of the post, and the
most interesting. In short, I knew a master machinist who could do
AMAZING things with a file and he changed how I look at things...
2) Make your own broach from a lathe bit.(with details) The orig
poster wanted a 10mm sq. hole in a 25mm aluminum cube. A square
cornered bar went thru the hole.
3) Triangle drill (as you mentioned above).
4) Drill and chisel w/re-ground wood chisel.
5) Make the part from two pieces C,I shaped; U,U shaped; L,L shaped;
which one depending on part needs. suggested aluminum pins and paint.
6) Pay a machine shop to do it for you. (the original poster is/was a
newbie to machining and had a sherline mill/lathe)
7) Redesign the part to accept a thru-bar with rounded corners so it
(the hole)could be milled.

This was all I posted, but:

8) EDM.
9) water jet.
10) Laser.

I felt these weren't really options for the man asking the question,
and besides, they are covered by "get someone to do it for you!"

That makes 13 so far... using 1], 2b], and 3] above.

Since I've got this post saved in notepad :-), I think I'll post it
to the sherline list. I was so frustrated, I didn't even want to re-
type it.

Thanks again, Brian.

Ballendo