DIY Punch Tool

This video shows how I build a punch tool for my new LED wall where I have to put in 1200 holes into sheet metal. The punch is made from mild steel and involved lot's of sawing, drilling and welding and other machining. I finally made some progress with TIG welding and share some tips that might help overcoming beginner struggles. To be able to aim where the holes go I added LED projected cross hairs.
It's tested and working with 1mm aluminium so far. Enjoy!
Links to the parts (affiliate links):
Belt Sander:
amazon.bitluni...
Metal Band Saw:
amazon.bitluni...
AC/DC TIG Welders:
amazon.bitluni...
TIG Finger:
aliexpress.bit...
amazon.bitluni...
AA Battery Case:
aliexpress.bit...
My camera and lens (4k 60fps):
amazon.bitluni...
plz share :-)
Check out my Tindie store to get some of my creations:
www.tindie.com...
Consider supporting my lab on Patreon for some extras and frequent updates:
/ bitluni
I'm also thankful for any donation on PayPal:
paypal.me/bitluni
Twitter: @bitluni
reddit: r/bitluni
#electronics #diy #maker #bitluni

[@ndanda1693]

A simple laser instead oft the led is what I suggest for accuracy. Nice build and a pleasure to watch!

[@Newera2047]

Laser will not spread Light rays so LED is good

[@cantfunction98]

I always appreciate how honest you are with your failures

[@besenyeim]

Commercial punches are usually not flat. You could grind a little curve into it, that would make it easier to use. It needs a little more support under it. A piece of round tube inside that square tube would do. Also, you used the I-beams in the "wrong" direction, that's why they bend so much.

[@bitluni]

I did that. Have even footage of it but it didnt make a clean edge for not much less force

[@dieSpinnt]

Google search for "hydraulic punching tool" and you will get loads of images with the diameters. ... and btw. these tools are also very nice in handling, precision and freedom of positioning. But can't score against bitluni's one, of cause;)

[@annego]

I love how happy you sound, when it works!

[@markusfuller]

That was a very satisfying build Bitluni. and your welding is much better than mine.

[@Trancelebration]

You can center punch your holes and add some spring loaded retractable cone inside your punch. Will give you much more precise hole placement.

[@andycrask3531]

Have a look at commercial punch tools and how the cutting edge is shaped. It is tapered so you get more psi and a shearing action requiring less effort and causing less wear. Great project though I'm looking forward to the finished wall.

[@ChunkySteveo]

That is some serious heavy metal work, impressive Bitluni!!

[@isojed]

Refreshing to see an build without an lathe. Shows one build anything.

[@iforce2d]

Finally somebody with a crapper drill press than me, your other new tools are making it look out of place :)

[@bitluni]

My grandpa gave it to me before he died. I used to play around in his workshop as a kid. He was a huge inspiration 😊

[@NicolaiWeitkemper]

That bitluni laughter - truly unique! :P

[@ZPdrumer]

for your first attempt, that is some amazing mechanical work and design. Even if it isn't your first time, it shows a lot of planning and foresight. Keep up the great work, both in your projects and videos P.S. I loved your TIG welding skills graph

[@vizionthing]

poor John Snow

[@_who_cares_1123]

You being Happy makes me Happy :D

[@contie144]

Klasse Arbeit. Schön das du dich so über deine Erfolgserlebnisse freuen kannst. Freue mich schon die fertige Ping Pong Wand zu sehen.

[@UnexpectedMaker]

That was awesome and really well presented! Also, great job on the punch and fantastic results from it!

[@fireofenergy]

The music is cool, too, for the background!

[@greggv8]

Either recessing it into one or between two tables, or building up a surface on either side to the level of the bottom half of the punch die will make it much easier to work with. The trick to not having your parts move around while welding is to tack weld a spot on each side first. If need be you can hammer the part back into alignment after the first and possibly second tack weld. Once you've held the piece with three tack welds welds it's not going move while you complete the rest of the welding.

[@frrapp2366]

nice build! a little late for you but a piece of angle for a fence mite have helped keep the metal in line so you only had to line up one direction looking for patterns for punch for my wife working in copper sheets

[@BorisSpark]

When welding thin material to thicker material face the torch towards the thicker material. Also you seem to get a lot of cold welding, it's when you don't get enough heat into the material and it doesn't bond properly, try adding another 5 to 10 amps on top of what melts material. I am not being mean, just giving an advice since I had to learn how to Tig weld aluminium, steel and other materials quiet quickly and I know it can be quiet hard to do it right and make it look nice and get a good weld. Best of luck on learning!!!

[@uint16_t]

The I beams should have been rotated 90 degrees for maximum stiffness. But your video is great and seeing your joy made me happy!

[@thepvporg]

The reason it flexes is because you orientated the I beam sections in the weakest orientation. You would need to infil with 1/4 plate and long weld the I section in to box section to add rigidity. The plate having holes drilled in so you can also weld to the I beam besides having beading joints, you have many that provide additional strength. I could suggest a mod where you have a motor running a gear ratio gear box to give torque to turn a cam that drives the punch bit, actuated by foot peddle and giving you both hands to then hold the work safely. You would be also best adding a clamp that is actuated to hold the work prior to pressing the part or hole.

[@user-iy9lb5jk6b]

Мужик красавчик! Получает от жизни удоволствие по полной. Обожаю его. Вот к чему нужно стремиться.

[@Kosh42EFG]

Awesome build!

[@WagonLoads]

With all of those punched discs, you can make Bitlunis...

[@CreativeJE]

I am hitting the like button on your every video

[@CirkaTusen]

How much force is needed on the rod to punch a hole like that? I wonder if it is possible to do automatically with two moveable axes. Great work as always!

[@AndrewAHayes]

an adjustable fence stop for your metal sheet will speed up your workflow massively.

[@Newera2047]

So nice punch design even I did it in 3D Model.... last year (covid time)

[@markusromeis3243]

if you want to punch a lets say 12mm hole in 1mm sheet metal the punch diameter needs to be 12.000mm and the die needs to have a innerdiameter of 12.100mm +-0.05mm for ideal results. The punch needs to be EXACTLY in the middle of the Die!!

[@SurajGrewal]

Just get a filter rod pushing pen... It has a mouse wheel like roller that you can rotate to retract or push rod with.

[@MrSwift2568]

thumbs up just for that welding skill chart

[@jaydmatacarita]

I would have used punch dies and welded them on. Also making it an a frame on top will make it more rigid. Either way thanks for building this. I'm inspired to make one.

[@AdityaMehendale]

How to simultaneously amuse and piss-off KZbin: 4:22

[@GertGybels]

Respect for the build, but you also could go to a waterjet facility and they'll cut you those whole in a matter of minutes and doesn't cost to much either. But, repect for the enginering part of it.

[@bitluni]

Probably, but I wouldn't learn anything

[@GertGybels]

@@bitluni you're 100% right. I just choose to gain time on 1 aspect to be able to spend more on other things to learn. I was approaching it from my POV. My apologies.

[@dj1NM3]

You really need a pair of pigskin TIG gloves, they are much thinner and form fitting like rigger's gloves, but have a gauntlet to protect your wrists from getting burnt from the UV arc rays.

[@Trent-tr2nx]

I hope you can make some 3d printed jig that allows you to line up the next hole based on the location of the previous one!

[@bamironhead9075]

When you are tig welding a large gag use your filler rod as bridge keep it down in the gag and move it back and forth with the torch head

[@JacksWailerTV]

Great work

[@SierraLimaOscar]

Careful where your fingers are when you grab the lever during punching

[@avejst]

Nice design, like the interaction with the real world Thanks for sharing :-)

[@johansen1010]

Wouldnt have bothered with a light. Make a guide fence and locating dowells .every hole will be accurate distance apart

[@KitarpLive]

I mean if u want to make a really good crosshair to punch the hole, you can just just paper and cut slits into get to get good resolution

[@markusromeis3243]

7:39 try 100-110 Amps because the 5mm I-Beam takes out all the heat. The other welds are nice.

[@TutorialHidroponik]

*I always laugh when you have a satisfied expression after punching a plate* 🤣🤣🤣🤣🤣🤣

[@Alex1zi]

Надо было просекатель немного сверическим делать и закалить его)

[@user-iy9lb5jk6b]

Потом сам до этого дойдет, он парень смышленый)

[@vizionthing]

Every single pro welder has produced the same quality welds. You dont get to 'Pro' without going through 'noob'

[@williangraterol2856]

Great Bitluni's!!!!

[@andyroa9904]

Can you make a multi size hole puncher sir. I mean a puncher with a replaceable punch bits I think.

[@ABID5]

Great video!!

[@vizionthing]

This does show why i beams are used the other way up :)

[@bitluni]

Yeah, but how do you put a hole trough the center of the beam if it's up right. It will twist if its not centered

[@AdamWelchUK]

Great build. Makes me want to buy some wedding gear. Can I have a souvenir bitluni coin please? :-)

[@lightdark00]

If you want a giant wall, then do four times what you plan 😜 It'll just be large 🙄

[@mattiasfagerlund]

Don't look into the laser with your remaining eye!

[@niggo7224]

(Sorry ich habe wig mit schutzgasschweisen vergliechen You dont have to clean the steel for welding it you can weld on the black) And just lay the bottle flat on the ground Just so you know it Du must bei der gas flasche aufpassen das sie nicht umfällt und der ventil abbricht und die flasche durch den raum fliegt. wenn sie liegt hast du das problem nicht so

[@_methm_]

I love this!!!

[@lightdark00]

Where's Cody on the welding chart? I don't know who those upper ones are.

[@DreitTheDarkDragon]

ToT is This Old Tony, works mainly with lathe, but sometimes welds with TIG. Totally worth watching, his video editing skills, machining skills and jokes are priceless :)

[@bitluni]

I thought of cody but actually I never saw him do tig. But i know that he won prizes for welding. 6061 is insane with aluminum

[@GuitoWorks]

hi i want make pogs of the 90 but i need but circles of 4 inchs how i can made this?

[@Dgtdggff]

do not use glooves when you work with tools that have spinning parts for safety reasons

[@Genusswurzel2009]

Geiles Teil 👍

[@TheTinkerDad]

Sooo.... a 3rd channel, something like Bitluni's Machineworks incoming? :)

[@bjarnehansen1101]

15:24 Looks like a lightsaber xd

[@TheRainHarvester]

Could a cnc, with a drill instead of a router, drill those holes in metal?

[@thomaspase9536]

18:00 ich würde Mal sagen, gut das du jetzt schweißen kannst 🤣

[@samGatzby]

what kind of steel you're using?

[@heltonritter]

Man, just take care to not smash your fingers in between when you are pressing down. Maybe you could cut out the upper sides, or make the lever a bit longer. Great!

[@vishwashehan8441]

i have a question can i control tasmota with internet all videos on youtube shows only working with Local Network

[@JohnJones-oy3md]

First three minutes of the video looked like you were fabricating some sort of slam-fire zip gun.

[@Digithalis]

Very useful idea also for other stuff like cutter possible ? :-)

[@Davedarko]

What the heck am I doing at 0:16? :D

[@hyperhektor7733]

not sure but it doesn't look really fast. Maybe with 2 people.

[@JeremyCook]

Do you have a video on the 312 LED wall?

[@Francois_Dupont]

woudnt it have been better to make a butterfly press? you just need a big big screw and some big lumber to make a U frame and its done.

[@bitluni]

Thought about this for some time and went with this design. Ita more compact and i can put it in the corner

[@Francois_Dupont]

@@bitluni it is sure less bulky, but you cannot do other project except punch holes in sheet. i am not saying you made bad thing just that a butterfly press could have made other project like forming stamping sheet metal into shape or removing/adding bearings into holes.

[@SpaceraverDK]

You should make a foot operated one.. A lot easier to do that way..

[@superwinderxd]

Woow 👍👍👍👍👍

[@ExplodingWaffle101]

can we get an f in chat for martin

[@Francois_Dupont]

Bitluni, how much is the normal cost for only a refill of welding gas (argon?)? in my country bottle are very expensive and i was wondering how much was for a refill of gas.

[@bitluni]

I paid 59€. That's on the high side but I don't live in the city anymore where its a bit cheaper. I bought a complete full and ne bottle for 130 on ebay. The i wasted much from the last one due to a leak in a hose. I fixed that now

[@Francois_Dupont]

@@bitluni wow, i thought it would have been much higher price. here the bottle only is 500$ i was wondering about the gas price. but 50$ for a refill is not so expensive.

[@p23q]

nice music!

[@bonafide9085]

Nice project, but laser cutting this thin aluminium sheet would not be expensive.

[@josecanedo007]

Niiiice

[@vinayladwal3096]

Use a small laser diode instead of led

[@bitluni]

Didn't have a fitting one.. but I tried

[@SurajGrewal]

Replace that led with laser cross (dual line) protector. You'll be surprised how small, the Chinese make em these days

[@janisgimbel8106]

Hi, kommst du aus Eiterfeld?

[@mohamedb5060]

wow to much of mechanical work what exotically is your specialty

[@markusromeis3243]

If you want i can help you with fabricating stuff (welding, drilling, turning, milling, ...) if you help me figure out how to 3D print.

[@ofsanjay]

Very interesting video. Watched from start to end. Learn a lot from your videos. [̲̅T̲̅][̲̅h̲̅][̲̅a̲̅][̲̅n̲̅][̲̅k̲̅][̲̅ ̲̅][̲̅Y̲̅][̲̅o̲̅][̲̅u̲̅]

[@homemadetools]

Excellent, subscribed! If you want more subs, feel free to embed your video on our homemade tools forum; looks like you're one of us :-)

[@McMan1ac]

Leitz "Dicke Berta" ca. 1918

[@FUKTxProductions]

dude, please dont leave your welder head laying on the ground, just for your own safty and my peace of mind

[@FUKTxProductions]

also for thinner and more fragile stuff, id suggest brazing

[@scrators]

Чернуху в аргоне варить.. в чем прикол?

[@SurajGrewal]

I've stick welded better looking joints (with help of a grinder) 🤣

[@BolverBlitz]

And your neighbors do not mind if you work in the garage and make loud noises?

[@bitluni]

I did the grinding during the day. The other stuff isn't loud

[@BolverBlitz]

@@bitluni My nieghbors even complain about loud noises even at day...

[@gezockt28]

Wenn jemand günstige LappKabel sucht, hab ich gestern gefunden, finde ich eigentlich sehr fair @t

[@matthiaskallenbach]

Wie finanzierst du dein Leben?

[@MichaelMantion]

why do youtubers think that their shitty choice of music makes their videos better. DEAR KZbinRS STOP ADDING MUSIC.

[@hollensted]

Geil!