Cut square hole in sheet metal?
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Lead Driver
Joined: Mar 2008
Posts: 7,182
Likes: 380
From: Near Los Angeles
Cut square hole in sheet metal?
Hey everyone. I need to make a patch for my truck bed. It needs to have a sq. hole for one of carriage bolts that hold bed to frame. I thought about welding together two pieces with L cuts to make a square, but it seems like a lot of work. Is there an easier way?
Edit: I should have checked YouTube before I posted. Here is the info I needed: https://www.google.com/search?q=how+...kPIP2vGR-AY_42
Edit: I should have checked YouTube before I posted. Here is the info I needed: https://www.google.com/search?q=how+...kPIP2vGR-AY_42
Hotshot
Joined: Feb 2004
Posts: 10,808
Likes: 2,604
From: The Shenandoah Valley
Typicaly, I just drill a slightly larger round hole, and use a carriage bolt and nut, and maybe washers. Nut pulls the carriage bolt in place. I use a drill gage to check for a hole that will still bite in the round hole. Example, 5/16" hole works for a 1/4" carriage bolt. If it's thin sheet metal, a washer helps so the nut will draw up tight. If it's thicker steel, a small file will easily make the 4 corners.
More Turbo
Joined: Feb 2020
Posts: 633
Likes: 84
From: AL
I was more referring to my meticulous, OCD nature. It's the main reason the back half of my truck is still disassembled from October 2020. I'm a bit of a perfectionist unfortunately, can't leave well enough alone.
Cargo Master
Joined: Jun 2014
Posts: 2,216
Likes: 324
From: Central Florida
Edit: I should have checked YouTube before I posted. Here is the info I needed: https://www.google.com/search?q=how+to+cut+square+hole+in+sheet+metal&sou rce=hp&ei=AzNRZMrLIrzMkPIPnNCz8Aw&iflsig=AOEireoAA AAAZFFBE2_KM-n2_J5H8EyvMzQ-sA3YtcgU&ved=0ahUKEwiK2aSFgNf-AhU8JkQIHRzoDM4Q4dUDCAs&oq=how+to+cut+square+hole+ in+sheet+metal&gs_lcp=Cgdnd3Mtd2l6EAwyBQgAEIAEMggI ABAWEB4QDzIGCAAQFhAeMggIABCKBRCGAzIICAAQigUQhgM6Dg gAEELOoCQCENkCEOUCOggIABCPARDqAjoICC4QjwEQ6gI6Dggu EIAEELEDEMcBENEDOgsIABCABBCxAxCDAToICAAQgAQQsQM6BQ guEIAEOggILhCxAxCABDoICC4QigUQsQM6CAguEIAEELEDOggI LhCABBDUAjoICAAQigUQsQNQpxhYzGNggoABaAFwAHgAgAGAAY gBrxGSAQQzNi4xmAEAoAEBsAEK&sclient=gws-wiz#kpvalbx=_FTNRZILkIuX3kPIP2vGR-AY_42
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More Turbo
Joined: Nov 2018
Posts: 563
Likes: 143
From: CA
I have used a triangular file to square a round hole many times. It doesn't take that long but this is a good alternative if you have the right sized chisels and a great anvil. What I have wished for but haven't yet found is a fixture for my pneumatic chisel that holds a file allowing me to exert pressure on both ends as it reciprocates back and forth at higher than my arm speed. It would need to reinforce the backside of the file lest I break all my files in half. Why hasn't this been invented yet or have I missed it?
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FTE Legend
Joined: Nov 2015
Posts: 30,912
Likes: 4,123
From: Angier, NC
What do you do when the part can't fit in a vice 
On my flare side bed side panel bolt lips before I welded them to the sides I drilled holes just the thread would fit through.
I then took a jigsaw to square off the holes using the bolt to test fit so it wouldn't be to big.
Dave ----
On my flare side bed side panel bolt lips before I welded them to the sides I drilled holes just the thread would fit through.
I then took a jigsaw to square off the holes using the bolt to test fit so it wouldn't be to big.
Dave ----
Moderator & parts slinger
Joined: Feb 2007
Posts: 50,186
Likes: 5,792
From: S/W Missouri, Polk county
Seen this? https://www.ford-trucks.com/forums/1...l#post17604608
Get the bed bolt kit that uses a allen wrench to hold the bolt head and then no need for the square to be cut.
"A little thread info thanks to SlickWillie about using the Ford bed bolts for a Superduty on our trucks.
https://www.ford-trucks.com/forums/1...ob-thread.html
Screw- N806251-S103 Nut- N803334-S439 The nut is/should be already pre threaded, or make sure you get them that way.
From Ford the screw is $19.60 EACH the nut is $13.20 EACH. OUCH
Or ck out Doreman kit #924-311
https://www.dormanproducts.com/itemd...SEName=924-311
From Summit $45
https://www.summitracing.com/parts/r...waAuqQEALw_wcB"
Get the bed bolt kit that uses a allen wrench to hold the bolt head and then no need for the square to be cut.
"A little thread info thanks to SlickWillie about using the Ford bed bolts for a Superduty on our trucks.
https://www.ford-trucks.com/forums/1...ob-thread.html
Screw- N806251-S103 Nut- N803334-S439 The nut is/should be already pre threaded, or make sure you get them that way.
From Ford the screw is $19.60 EACH the nut is $13.20 EACH. OUCH
Or ck out Doreman kit #924-311
https://www.dormanproducts.com/itemd...SEName=924-311
From Summit $45
https://www.summitracing.com/parts/r...waAuqQEALw_wcB"
Cargo Master
Joined: Jun 2014
Posts: 2,216
Likes: 324
From: Central Florida
Right, the gizmo I imagined would have to work that way too.
More Turbo
Joined: Nov 2018
Posts: 563
Likes: 143
From: CA
Seen this? https://www.ford-trucks.com/forums/1...l#post17604608
Get the bed bolt kit that uses a allen wrench to hold the bolt head and then no need for the square to be cut.
"A little thread info thanks to SlickWillie about using the Ford bed bolts for a Superduty on our trucks.
https://www.ford-trucks.com/forums/1...ob-thread.html
Screw- N806251-S103 Nut- N803334-S439 The nut is/should be already pre threaded, or make sure you get them that way.
From Ford the screw is $19.60 EACH the nut is $13.20 EACH. OUCH
Or ck out Doreman kit #924-311
https://www.dormanproducts.com/itemd...SEName=924-311
From Summit $45
https://www.summitracing.com/parts/r...waAuqQEALw_wcB"
Get the bed bolt kit that uses a allen wrench to hold the bolt head and then no need for the square to be cut.
"A little thread info thanks to SlickWillie about using the Ford bed bolts for a Superduty on our trucks.
https://www.ford-trucks.com/forums/1...ob-thread.html
Screw- N806251-S103 Nut- N803334-S439 The nut is/should be already pre threaded, or make sure you get them that way.
From Ford the screw is $19.60 EACH the nut is $13.20 EACH. OUCH
Or ck out Doreman kit #924-311
https://www.dormanproducts.com/itemd...SEName=924-311
From Summit $45
https://www.summitracing.com/parts/r...waAuqQEALw_wcB"
Moderator & parts slinger
Joined: Feb 2007
Posts: 50,186
Likes: 5,792
From: S/W Missouri, Polk county
