Other uses for a punch/flare die?

[Zzz]

I'm going to buy a Mittler Brothers punch and flare die for making some flanged lightening holes in a piece of .020 that I need to stiffen and prevent from oil canning.

What is a good size to buy that has another common usage? Was planning on 3".

[marcusofcotton]

If you were to bump up to 3 1/8", you'd be able to use it for instruments as well. Also, for my hands, 3 1/8" lightening holes are easier to get my hand in and out for service work.

[Bdflies]

Those punches are some nice tools! A buddy has several sets, from 1 1/2" to 4" and I've used them, occasionally. They do a great job.
I know you didn't ask for an alternative to the flanging tool, but a bead roller is another way to stiffen a panel and eliminate oil canning, if it's a panel that wouldn't do well with holes.

Bill

[S Lathrop]

Here is an idea for flanging that is way less expensive that buying flare dies.

This is how I did all ribs and other parts that needed stiffening. The top is a picture of the nose rib. The next two parts are the male and female die parts and the third is a wood block. Because the ribs were flanged, the block had to fit inside rib. The aluminum in this case is 1/8 inch thick but other thickness could be used for a deeper flange. Making this tooling is the only time I used a fly cutter. All other holes I cut with a router and had a wood block with the correct hole size as a guide for the router. All the pieces are lined up with dowel pins and the part is formed in a press. I used MFD board on either side of the material being pressed.

In the case of the nose rib, the female die is placed on the wood block. The rib blank goes nest and the male die (the round parts) are placed on top of the rib. Another piece of wood is placed on top and the whole thing is pressed. If you don't have a press, you can use a bottle jack on the floor and may be a truck or something else to press against.

The dies do not have to be round. I have made tooling like this for oval and rectangular shapes.

[Zzz]

Those punches are some nice tools! A buddy has several sets, from 1 1/2" to 4" and I've used them, occasionally. They do a great job.
I know you didn't ask for an alternative to the flanging tool, but a bead roller is another way to stiffen a panel and eliminate oil canning, if it's a panel that wouldn't do well with holes.

Bill

Bead rolling would be my first choice actually but the problem didn't present itself until after I'd fastened my sheet to the seat frame.

https://flic.kr/p/xmYVjA

I believe this makes using a bead roller more difficult or not possible? I'd love to roll an X shape through that seat back.

I think punching some flared lightening holes will accomplish the same thing though. I hope.