how can i punch/cut a hexagon hole in a sheet of metal?

my worx oscillating saw uses hexagon holes to attach blades to it

my idea is to make my own blades for my oscillating saw. basically my plan is to cut up a wood saw in to strips and cut/punch hexagon holes in to them to make cheap blades.

my problem i a ham fisted gas bloke that knows nothing of the world of metal work

any idea to the cheap/fastest/repeatable way of doing it?

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http://www.homegas.co.uk

The metal is likely to be hardened. I would not be suprised is a hacksaw or HSS drill dit would not touch it - or blunt before you've done 1 cut / hole. So cutting the hole is pretty much out. Punching the hole out would be another way but again because the metal is hardened it will be brittle making it difficult or impossible even if you had the right tools - a hydraulic press and punch and die.
So basically you can't. Sorry.

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Mike

fully agree with mike
a non starter

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we are all ------------------still learning

a bit pessimistic

lucky I ignored you lot, though what you said was completely true!!! the hacksaw blade was blunt halfway through cutting and the hss drill bits did not even touch it...

but being bloody minded and having an whole bunch of tools i found a way

for cutting the saw up i found that air shears running off my compressor managed to cut it(though it did struggle a little)

and lucky for me that worx oscillating saw comes with this adapter
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which grips the flat metal.

so all I need to do make a 10mm hole. as the hss drill bits did not even touch the metal. what i did was heat the metal up till it was red hot and punch a small hole.

this also pushed/bulged the metal out a little. so i grinned the metal down, heated the metal up again and then used a 10mm hss drill bit to make the hole.

now i knew that heating it up would chance the hardness so i kept the heat to one end of the metal and away from the cutting end.

i use an old wood saw and a tenon saw and make 12 blades out of them. they cut really well. the tenon saw blades are better though. was thinking of making a guide as it turned out so well

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http://www.homegas.co.uk

Im sure i have had this discussion before, about hacksaw blades.
There isnt an issue drilling through a hacksaw blade, i dont see why a wood saw should be any different.
Most likely junk drill bits.

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Why isn't the number 11 pronounced onety one?

yes, they were the cheapest hss bits you could get

the 10mm bit is now a completely rounded

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http://www.homegas.co.uk

Get a cobalt bit

I drilled a number of holes trough a hacksaw blade to prove a point, picked up the first drill bit that came to hand. Dont think i own a single cobalt bit. Never had a problem with quality hss drill bits, so never looked any further.

For speed and repeatability, you want a turret punch/punch press. Probably cheaper to buy ready made blades than buy one.

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Why isn't the number 11 pronounced onety one?