How to make a square hole

How to make a square hole

How to make a square hole in any workpiece? Anyone can drill a round hole, but sometimes you need to make a square hole.
How to make a square hole

I needed to make a large square hole in a round blank so that the bar square, firstly, could move freely in the hole, and, secondly, so that there would be no large backlash. That is, you need a hole for a square of ideal shape and size. So the question arose - is it possible to do this with your own hands, not in a factory?
How to make a square hole

I have already had to do this, and therefore I answer - it can be done, but in the absence of a certain set of tools, it will not be possible to make a high-quality hole.

Will need


So, what is needed to make a perfect square hole:
Milling machine with cutting and slotting disc cutters, electric arc welding machine, lathe.

Making a square hole in metal


In order to make a square hole, we perform the following steps:
We clamp the workpiece in the milling machine and use a disk cutter to grind out a rectangular groove;
How to make a square hole

It turned out that the work goes much faster with a cutting cutter, and so I had to use it instead of a groove cutter. We perform a reverse replacement and, using a groove cutter, clean the corners of the workpiece.
How to make a square hole

We insert a square piece into the resulting groove, and another rectangular piece of metal into the remaining open upper part.
How to make a square hole

How to make a square hole

We weld this small piece to the main blank with an electrode using conventional arc welding.
How to make a square hole

How to make a square hole

We clean the resulting element from adhering metal, which is best done using a lathe, completely turning it out and grinding it.
How to make a square hole

As a result, we get a round blank with a perfectly square hole.
How to make a square hole

How to make a square hole with improvised tools


All these technological cycles can be done with the help of simple improvised tools, using only an angle grinder, which is popularly called an “grinder”, a vice and a welding machine.
But in this case, firstly, you will have to sweat a lot, and, secondly, the product will not turn out so smooth.
When performing this work, it is imperative to comply with safety requirements:
  • when working with milling and lathes, mechanic's glasses are required;
  • When performing welding work, gloves and a welding mask are required.

This is how, if you wish, you can make a square hole of any size no worse than the factory one!
How to make a square hole

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Comments (49)
  1. Guest Oleg
    #1 Guest Oleg Guests 12 March 2019 15:15
    79
    Of course, not in a factory setting; everyone has a milling machine lying around idle in their bedside tables
  2. Guest Sergey
    #2 Guest Sergey Guests 12 March 2019 15:33
    36
    Yes, you're a funny joker!
    If you also had a slotting machine, you would make the square even easier and faster!
    1. alex
      #3 alex Guests 24 March 2019 20:19
      0
      You can probably push it into a lathe, ala a slotting cutter, and continue the slotting with a manual drive. If it is undesirable to heat and saw, then this is a completely viable option. It is not difficult to make such a cutter from a lathe.
  3. Sector
    #4 Sector Guests 12 March 2019 15:36
    65
    Or maybe just buy a small factory to make a square hole? I went to the store and bought it. Where would an ordinary hobbyist get a milling machine or lathe? Well, okay, we can look for welding in garages. But why fence a garden?
    1. Guest Gerasim
      #5 Guest Gerasim Guests 12 March 2019 17:19
      5
      That's what it says at the end... no lathe... put the grinder in your hands and go!
    2. 956
      #6 956 Guests 14 March 2019 08:37
      2
      Where will you get welding? And every shipbuilding circle has a lathe. Some aircraft models even have milling ones. But the hole is not “kosher”. Firstly, the seam is still not the base metal. Secondly, how to guarantee penetration to the full depth of the hole, but simultaneously keep the shape? The cutter must move inside the hole and it is the movement of the cutter that should determine the shape.
      1. Andrew
        #7 Andrew Guests 14 March 2019 15:09
        3
        Welding is sold at any power tools store and costs a little more than an angle grinder.
  4. Guest Yuri
    #8 Guest Yuri Guests 12 March 2019 18:13
    3
    In some cases, you can weld a square pipe (standard or homemade from two corners) into a round hole.
  5. Guest Alexey
    #9 Guest Alexey Guests 12 March 2019 18:35
    5
    Plasticine square.
    A little load and the welding will flow.
    Like an overheated wax candle.
  6. Guest Sergey
    #10 Guest Sergey Guests 12 March 2019 20:04
    34
    You just need to use a square drill)))
  7. Guest Victor
    #11 Guest Victor Guests 12 March 2019 20:19
    12
    Drill out with a drill, finish with a file.
  8. Stanislav
    #12 Stanislav Guests 12 March 2019 20:44
    5
    for this there is a piercing machine, and not this pain in the ass, or a store where you can buy this so-called key
  9. Locksmith
    #13 Locksmith Guests 12 March 2019 21:23
    6
    At home, we drilled a hole close to the size of a square. If the size is large enough, take a triangular file and make at least one corner (if the hole is not blind). Then take a small hacksaw (there are some about 5mm) and cut through the remaining 3 corners. If the hole is small, you will have to finish the job with a triangular file. For a blind hole, it is easier to make a bushing with a square hole and put it on the square.
  10. Guest Sergey
    #14 Guest Sergey Guests 12 March 2019 21:45
    5
    So many body movements, horror...
    A simple lathe is enough, just drill a hole of suitable diameter and press out a square...
    Well, if you really need such precision, you can sharpen the feed...