How to cut holes in .002" thick brass shim stock

[throwback]

Looking for input on how to cut holes in .002" thick brass shim stock. I have tried to drill the .002" thick shim stock and it is very thin and tears. What is the best way to cut holes of specific sizes 3/8", 1/4", 5/8" & 1/2" holes in this thin material? I am using this on a head gasket to redirect the water flow to the back of the engine.

Thank You!

[Terry,OH]

What year Ford flat head? Ford has head gaskets that have smaller water passages in the front than the rear to do exactly what you want.
The gaskets are for the later 24 stud engine and not the 36LB
A hole punch for gasket material will deform the brass, drill and back the brass with hard wood or Masonite.

[Bassman/NZ]

Originally Posted by throwback

Looking for input on how to cut holes in .002" thick brass shim stock. I have tried to drill the .002" thick shim stock and it is very thin and tears. What is the best way to cut holes of specific sizes 3/8", 1/4", 5/8" & 1/2" holes in this thin material? I am using this on a head gasket to redirect the water flow to the back of the engine.

Thank You!

The hole punches used for sheet gasket material might work. You would need a heavy, flat chunk of wood underneath the brass.

[throwback]

1936 LB engine.

[joel]

There are 2 ways that I've done it. the easiest is to use punch and die set sold by places like MSC. http://www.mscdirect.com/FlyerView?c...alogs/big-book I also have cut shims using a Blair cutter and 2 small pieces of aluminum with the shim clamped between them. I used !/8" thick aluminum and clamped the " sandwich" to the mill table. That punch and die set works the best, and if you know any diemakers or moldmakers, they may help you out.

[RoadsterA]

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Ive had success with clamping the material between 2 pieces of hard wood then drill throw all.Its a little tricky to gauge exactly where your drilling, but with some careful measurements all good.

[Jim Boehmke]

put the shim stock on any hard plastic surface or Formica type surface and use an Exacto knive with the pointed blade

[Kube]

You'll find it easiest to use a die set. The materiel must be held firmly within the two "halves" of the die. A punch is then struck through the hole, pushing out the "slug".

[296 V8]

Leather punch … commonly use for making holes gaskets

[Bob G/Spanaway]

Harbor Fright sells a cheap shim punch set that works fine for occasional home use.
Has a series of holes from about 3/16 to 5/8 or so.

[JWL]

I have done it several different ways. For me, the best method is to sandwich the thin brass or copper or aluminum or steel pieces between heavier pieces of steel and clamp tightly and then drill. If placement to a specific location is important I drill a slightly smaller hole(smaller than the finished hole I want in the thin brass) in the top heavy piece through which I can view a center punch mark made on the thin piece. You can do one piece or several thicknesses of the thin material when sandwiched and clamped as close to the hole as the drilling machinery will permit.

[Cool Hand Lurker]

You can do this with a simple ball peen hammer. Drill a hole in a chunk of steel that is the size you want for the hole. This will be your die. Place the sheet of brass over that hole and lightly hammer on the brass around the edges of the hole until you cut through. This works nicely for cutting regular gaskets also.

[PeteVS]

Don't know if this will work, but try melting some wax onto a block of brass or whatever. Then, heat up your shim sock and press that down into the wax. Drill your hole and then heat up the block to peel off the shim. Probably wont work but if nothing else does.....

[BillLee/Chandler, TX]

Have a similar need for model airplanes: making head shims to adjust compression. Here is an article that show the typical method:

http://www.nclra.org/TechTopics/MakingHeadShims.pdf

[Flat32]

I use my drill press for punching gasket holes. I just stick common hollow hole punches in the chuck and the spinning punch cuts more cleanly. Often just take a piece of steel tubing and use a three sided scraper to carve/machine the inside end to a sharp edge and finish it off with a flat file on the outside diameter. Works better for me than hole punches that have the edge taper on the outside diameter, inside taper doesn't distort the gasket. Even copper works on gasket material. I use hard plastic to back it up, wife's discarded cutting board.

Steel should work on your .002 brass. Try it on a piece of Coke can material.

Flat32

[41ford1]

Originally Posted by Bob G/Spanaway

Harbor Fright sells a cheap shim punch set that works fine for occasional home use.
Has a series of holes from about 3/16 to 5/8 or so.

Harbor Freight #95547. For occasional use it works well.

[TagMan]

I use a leather punch tool that has several different size punches on a wheel. You rotate the wheel to the size punch you want, slip the part to be punched between the jaws, squeeze the handles and punch the hole. I've used it for punching holes in light shim stock for years. Can't remember where I bought it, but I'd Google it or check a local hobby shop for one.

[cmbrucew]

For a perfect 1/2 " hole, drill a 1/2 inch hole in a piece of steel. Hold your shim stock over the hole, place a steel ball, larger than 1/2 " on the shim stock over the hole, strike with a hammer. If you cannot find a steel ball, you can use the peen end of a hammer over the hole and strike the other end with a soft hammer or wooden mallet.

Bruce

Works good
Lasts long time