DIY punch set

[zizi666]

A saw a similar device in a thread on rivets and since I have acces to a workshop (working in a factory has its advantages) I decided to create one.
ingredients : some scrap plexi (thick) 2 bolts and wingnuts, assorted drills, scrap iron rod and a lathe and a piece of 1mm thick electrode rod.
after cutting the plexi into 2 equal parts I wrapped some tape around it so they would remain in place.
I then drilled 2 holes (6mm diameter) for the bolts (M6) to fit in.
screwed the wingnuts on and tightend the lot.
next step was drilling the holes. I went for 1 / 1,5 / 2 / 2,5 / 3 / 3,5 / 4 / 4,5 / 5 / 6 / 7 / 8 / 9 / 10mm
On the Lathe I turned matching pins. (Well, at least for 3 / 3,5 / 5 / 7 and 8mm)
for 1mm I use the piece of electrode.
I'll have to look what to use for the other small diameters and I still have to make the other large pins.
and this is what it all looks like :



and here with some punched out styrene sheet :

[Schlumpfsa]

Superb, love it.  Cutting small circles is such a chore and scrapbooking punches are so expensive.

[snitcythedog]

The machine shop works.  I did the same thing with brass tube, steel rod, plastic and resin.  Worked great, but did not last so well.  I bought one similar to the one that you made so I am real envious that this one was out of scrap.  Next one that you might try is to do a hexagonal punch.  I still have not got my head around that one.  Great job.
Snitchy sends.

[6milPhil]

Good work... can you sell me 1000 rivets please?

[zizi666]

The machine shop works.  I did the same thing with brass tube, steel rod, plastic and resin.  Worked great, but did not last so well.  I bought one similar to the one that you made so I am real envious that this one was out of scrap.  Next one that you might try is to do a hexagonal punch.  I still have not got my head around that one.  Great job.
Snitchy sends.

The edges are a bit rough and the small ones aren't always 100%, but good enough to my taste.
One problem that could arise is that the holes for the bolts get worn and as such the punching holes would no longer aline.
Ofcourse that won't happen overnight, so I guess I'm safe for a while.

As for the hexagonal punch. We've got the machinery but I'm lacking the knowledge and definitly the authorisation to operate it. 
The machine I'm talking about is a spark erosion machine. Basicly you'd have to create a hexagonal rod and use it to erode through blocks of steel. Afterwards you use the rod to punch the hexes.  the downside would be no visibility when you insert your sheet material.

[zizi666]

Good work... can you sell me 1000 rivets please?

Aaaargh... I thought it was already taking hours just to make that small bunch 

[Brandlin]

Hexagonal is fairly easy.

Hex bar is reasonably available and the acrylic sheet can be laser cut very accurately to make the necessary hex holes.

A little google-Fu shows that Historex used to make a hex punch set http://www.historexagents.com/shop/tips_punch.php

Blast models still do both round and hex http://www.phpshopxml.com/blamod.shop/CID/df84a89337e5f5f65d2cc10518f7f132/function/itemPageDisplay/shopItemCode/AED00H

Micro mark make a round set http://www.micromark.com/Micro-Punch-Set,8603.html and are rumoured to be making a hex one. (not cheap but depends on how often you use it!)

[aircav]

You could always make the bottom plate from Stainless steel that would last longer, the top should be ok out of plexi as its only really a guide 

[zizi666]

You could always make the bottom plate from Stainless steel that would last longer, the top should be ok out of plexi as its only really a guide 

True. I only figured that out when I followed Brandlin's links 

[aircav]

True. I only figured that out when I followed Brandlin's links 

Well when you make another set i will have one 

[6milPhil]

Yep me too. 

[snitcythedog]

The edges are a bit rough and the small ones aren't always 100%, but good enough to my taste.
One problem that could arise is that the holes for the bolts get worn and as such the punching holes would no longer aline.

Happened with mine too. Rough edges, and it wore out.  Took a good long time though.  As long as the punch is not allowing the plastic to form a cone, your plastic cement should round the edges nicely. 

Well when you make another set i will have one 

Yep me too. 

And a cottage industry is born. 
Snithy sends.

[Grimmnar]

Superb, love it.  Cutting small circles is such a chore and scrapbooking punches are so expensive.

2 bucks a punch is expensive? :-)

Grimm