I had to punch holes in a steel computer case earlier so that it could accommodate a new case fan. Sure, I could have used a drill, but I reached for my Roper Whitney No. 5 Jr hand punch. Gosh, it’s a great tool.
The No. 5 Jr hand punch is a light duty tool, but it’s great for punching holes in aluminum or thin steel. With a maximum capacity of 1.2 tons, the No. 5 is fairly capable. Since it sacrifices leverage for portability, you’ll want to use a bench mount when punching many holes.
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Roper Whiney No. 5 Jr Sheet Metal Punch via Amazon
Product Info via Roper Whitney
You can usually find this hand punch complete with a set of punches and dies via Enco or MSC (check their sales flyers) for $75 or so.
While knock-off import designs are available, their quality will be far behind that of the Roper Whitney. When it comes to punches, quality can make a HUGE difference in efficiency and user comfort.
For a little more about how to use this tool, check out step 7 of “How to Work With Sheet Metal” over on Popmech.
jeff_williams
How big of a throat does it have? It seems like you would have to punch near the edges of the case.
Stuart
The throat is 1-3/4″ deep. Once a fan hole is cut with a hole saw or a Dremel with circle cutter attachment, the mounting hole positions are within easy reach of the No. 5.
Some case fan positions require drill-bored mounting holes, but the holes for top or side-panel-mounted fans can usually be punched with ease, even if they’re still attached to the main chassis.
IndyEngineer
I like your tool choice for that job, Stuart. I’m sure your punch made a much cleaner hole than a drill bit would have.
uthscsaedu
If I recall correctly, Stuart has superhuman strength.
What tool can I use if I have regular strength?
Stuart
The holes are indeed (usually) cleaner, but they’re quicker too. No pilot-hole necessary.
Uthscsaedu, these types of punches can be used with regular strength as well. But as mentioned, for lots of holes the optional bench mount or a custom-made bracket will definitely come in handy. It takes a lot less effort to squeeze one handle while the other is held fixed to a bench than it does to squeeze both handles together manually.
jeff_williams
Oh, I thought you were using the punch to swiss cheese the case to use as the fan grate. I didn’t realize you were cutting a the fan hole first and just using it for the screws.
Stuart
Well, you can swiss-cheesify a case panel with a hand punch or drill bit, but it’s far easier to buy perforated metal, “modders mesh” or similar sheet instead.
Not to mention, a perforated sheet will usually look a lot better due to the more precise hole pattern.
Dave
Stuart, have you found anymore uses for this punch. Trying to find a reason to get one as it looks like a awesome tool but it probably won’t get much use. Once/twice per year.