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Adding countersinks to formed stainless sheet metal

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Hello, I’m working on a sheet metal enclosure (as in the image) that requires flush mounting for M6 countersunk screws. I need to add a countersink on a few holes, but the part is already flat-cut and formed. Has anyone successfully added a countersink post-process in this kind of setup without warping the part? Looking for the most practical approach, either manual or otherwise.

    • D

      Hello, I’m working on a sheet metal enclosure (as in the image) that requires flush mounting for M6 countersunk screws. I need to add a countersink on a few holes, but the part is already flat-cut and formed. Has anyone successfully added a countersink post-process in this kind of setup without warping the part? Looking for the most practical approach, either manual or otherwise.

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    • D

      Yes, I’ve dealt with this exact scenario. Adding a countersink after forming is doable, but you’ll want to proceed carefully to avoid deforming the part, especially since you’re working with stainless, which is tougher than aluminum or mild steel. The safest manual method is using a hand deburring/countersink tool with a depth stop. It gives you full control, and since you’re only working with a 2 mm thick sheet, it won’t take much effort. Just make sure to clamp the part securely on a flat surface to prevent flexing while you work. Go slowly and check the fit with a sample M6 countersunk screw as you go.

      If you have access to a drill press with variable speed and a good quality countersink bit, that’s another reliable option. Keep the RPMs low and use a sharp bit to reduce work hardening or generate heat that warps the part. Support the sheet fully underneath. Don’t let it hang or flex.

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    • M

      Avoid aggressive CNC countersinking unless the part is fixtured really well; otherwise, you risk creating a twist or stress in the sheet. If this is a recurring need, you might want to look into press-style countersinking dies, which can dimple the countersink rather than cut it.

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Adding countersinks to formed stainless sheet metal
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