Tools I Frickin’ Love | 5 Office-Friendly Hand Tools [Sheet Metal Edition]

The rotary tool (Dremel) is the ubiquitous hand tool for low skill prototyping. The magic wand of the prototyping world. And by that, I mean it can make sparks, dust, and smoke. The real magic is how all those theatrics can produce such a small cut (and leave such a razor-sharp edge). It is time for you to level up your prototyping game from a level 4 spellcaster cowering against Timeline Trolls to a level 37 mage with a permanent aura of undefendable design domination. Now behold the amazing Dan and his workshop of wonders!

1. Nibbler

Also called:
Adel Nibbling Tool, Nibbling tool

Also a great name for:
An adorable doe-eyed extraterrestrial monster that can eat 100 times its weight in toxic space junk.

How it works:
Tin snip style – Squeezing the lever handle applies compound leverage to a cutting jaw that rips up a short swath of material. It shears the sheet along two parallel tracks creating a roll of waste material. Think of it like this, a front loader with its scoop skimming under a road moves forward a bit and lifts and then lowers and repeats the process, rolling up a track of asphalt. Continue squeezing away as you trace your pattern or freestyle. This tool is very easy to pick up and start using immediately but takes a little time, hand strength, patience, and skill for larger and more elaborate pieces.

Punch and die style – squeezing the handle pulls the blade through the material against a fixed die and removes a tidy rectangular scrap. For internal holes, first drill a pilot hole then push the cutter through the hole. To use the road analogy, think of the Hulk punching a fist-shaped hole and then punching an adjacent fist shaped hole and so on down the line.

Why it’s awesome:
Production sheet metal involves large and costly machines with expensive set ups and long lead time. For iterative prototyping or one-off test equipment, these nifty little tools provide an option to DIY. Cleanly cut sheet with minimal deformation or distortion up to relatively thick material depending on the its hardness. Cut non-round shapes. Make inside cuts. Modify already built assemblies or sheet metal parts that are already bent or formed. Pro tip: For best results, while using the tool, in a Pac Man cadence, say “nibble, nibble, nibble, nibble…”.

Awesome pairing:

• The sheet metal section of the McMaster Carr catalog
• Scriber, sharpie, and a printed template
• Spray paint
• File
• Control panels
• Edge trim and bushings

Our Pick:
Knipex Tools Sheet Metal Nibblers

2. Ratcheting Bar Clamps

Also called:
One-handed bar clamp, Trigger-Action Bar Clamps

Also a great name for:
A professional wrestling move

How it works:
Each squeeze of the pistol grip handle moves the clamp jaws along the connecting bar closer together until they make contact, at which point squeezing the grips applies increasing pressure to the contact surfaces. Pull the release trigger to disengage the jaws and slide them apart. Rubber pads on the jaws provide grip and prevent surface damage. You can unmount and flip the mounting direction of the jaws to change the action from push to pull to use it as a spreader. Available in sizes from hobbyist miniatures to construction grade.

Why it’s awesome:
These are like an extra set of hands (of your beautiful assistant) when you need some. Except better because they can apply both increased and consistent clamp force. To hold your workpiece to your work surface, hold two pieces together while you match drill or to allow for adhesive curing, and hold six pieces together, have a healthy snack, and then release them, simply because you can. They sell special attachments, and I have even 3D printed attachments that fit the ends for custom purposes like mating rubber molded connectors.

Awesome pairing:

• 2012 Pinot Grigio

Our Pick:
IRWIN QUICK-GRIP Clamp Set

3. Deburring Tool

Also called:
That curvy thing with the handle

Also a great name for:
Alexander Hamilton’s pistol

How it works:
It is a handle, often pen-shaped, with a curved swivel blade. Lightly drag the blade portion along the raw edge created from a machining operation. A delightful curlicue of material is removed leaving a chamfered and burr-free edge. A variety of swivel blades exist for different purposes and materials and can be swapped out. Other deburring apparatus also exist for specific purposes like dual sheet edges or outer tube edges.

Why it’s awesome:
This tool is extremely easy to pick up and use for even the greenest wizard’s apprentice (no sleight of hand required). Deburring parts add that little extra level of finish and professionalism. After all the work of designing and fabricating a part, it would be a waste to pass up this final polish freebie. Moreover, sharp edges and burrs are a cut risk. When 3D printing, I use the brim option to ensure good build plate adhesion. The deburring tool works as an excellent debrimming tool. Like the automatic center punch, this tool is cheap, simple, effective, and although seemingly for a niche purpose, ends up getting used frequently.

Our pick:
General Tools 482 Swivel Head Deburring Tool with Metal Handle

4. Stepper Drills

Also called:
Unibit, Multi-diameter Drill Bit

Also a great name for:
An exercise that really works the glutes. Come on! Gimme three more!

How it works:
A conical shaped, stepped bit with a straight-flute (cutting edge) capable of cutting multiple, incremental holes up to large sizes. Customarily called out by the minimum and maximum hole size and the step increment, and the step hole diameter is labeled inside the flute. Can only cut material thinner than the step size (usually 3/16”) however it can cut thicker material of the largest hole sizes. Self-starting versions don’t require a pilot hole (non-self starting do) and have a split point self-center that prevents walking. Available in metric and inch sizes.

Why it’s awesome:
It can cut large, precise, and clean holes quickly and easily. It is the extremely rare instance where a version of a tool with more applications not only doesn’t compromise but can perform just as well or even better. Sometimes a specific hole size is required that isn’t one of the incremental sizes available or you have a thicker material. Sometimes you just need a big hole. Maybe just a large hole to pass cables through or for a smartly designed part that fits in standard hole sizes. It is excellent at drilling sheet metal, as spiral flute drill bits may tend to grab and deform when cutting into thin metal. A super extra bonus is that the angled transition between steps can be used to chamfer and deburr hole edges.

Awesome pairing:

• Project boxes

Our Pick:
CO-Z 5pcs Hss Cobalt Multiple Hole 50 Sizes Step Drill Bit Set with Aluminum Case

Side Note:
I just had the startling realization that I have written 250 words describing the function and my affinity for a drill bit. I will be doing some soul-searching.

5. Automatic Center Punch

Also called:
Spring loaded center punch

Also a great name for:
A textbook boxing wallop to the midline

How it works:
Align the point of the tool with the location on the material where a hole is ultimately desired. Then press down on the handle until an internal spring mechanism releases an impulse, driving the point into the material. Presto chango. A dimple in the material is created. Turn the end of the handle to adjust the spring tension to make lighter or heavier marks. The sole purpose of the dimple is to align the point of a drill bit and prevent wandering or walking. Resulting in a hole exactly where you intended. Special purpose versions exist for hinge holes.

Why it’s awesome:
First, the click and subsequent release are always satisfying. When compared to the alternatives of a hammer and center punch, or mounting your workpiece to a machine and visually or by using readouts aligning the bit combines the speediness and elegance of the ACM are obvious. Compact, reliable, easy to use, effective, and affordable. These are the magic ingredients for a tool that gets actually used, and a tool that gets actually used is the best tool. Also, it can be used in an emergency situation to break glass windows (true) or for marking multiple locations to connect the dots.

Awesome pairing:

• Hand drill
• Drill press

Our Pick:
TEKTON 6580 Automatic Center Punch

Alakazam! Your mages satchel is now filled with many powerful and enchanted items (and some helpful tidbits). The wise and powerful Dan must now attend to his many other pressing and important matters! *Poof*

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