working 0.005″ titanium foil

Hmmm. I may have to give that one a try. Thanks.

–B.G.–

Bob, if you don't already have a good leather punch, don't waste your money. I tried that on 6Al-4V .003" titanium sheet, and it hardly made a dent. I can't see how it could possibly work on your .005" stuff, unless maybe if it was CP-2 and not 6Al-4V (but probably not even then…).

OK, I will scratch the leather punch off my list.

–B.G.–

> if you don't already have a good leather punch, don't waste your money.
+1

Cheers

> a cheap chisel would be the easiest, suitable tool for making small, square holes

"Now there's a thought! I'd drill the corners first to avoid stress concentration though."

Absolutely, I tend to drill the holes first then 'join the dots' with a chisel/jigsaw/hacksaw.

I have a full set of Snap On hole punches which I'd thought of using, but after seeing how tough 0.20mm titanium is, I vetoed that idea as I don't want to destroy the punches!

I'll use 'em on 0.005" stuff though.