How to make a square hole in thick metal? Step-by-step instruction

The disposition is as follows. There is a metal cylindrical blank, in which you need to make a hole for a square rod.

To do this, you need a lathe. Cutting and milling disc, as well as a cutter. For this task, a VK-8 cutter was used. You also need a welding inverter.

The idea is as follows. A rectangular cut is formed longitudinally in the workpiece, with a width corresponding to the size of the side of the square to be drilled. The depth is selected taking into account the dimensions of the workpiece so that the center of the future square coincides with the axis of the cylindrical workpiece.

Then a metal jumper is installed over the cut, which will need to be scalded.

To give the product a presentation, it should be processed after welding on a lathe.

For cutting, it is better to use a cutting disc. This will greatly speed up the work. Let's not forget the oil.

We change the disk to a milling disk, since we need the correct geometry of a square hole.

We place a square rod in the cut. We put a metal jumper on top. As the latter, we use a segment of a similar rod.

Using a vise, we fix the workpiece prepared for welding.

We grab the jumper for a couple of points and take it out of the vise. We weld the structure well.

So as not to think, we anneal the welds.

For processing, a VK-8 cutter was used. We expose the workpiece. To do this, I had to process it a little with a file.

We turn the product. We expose and trim the workpiece.

We clamp and process for finishing.