Running into trouble punching a 9/16 square hole over an existing 9/16 round hole in 1/2" 1080 wear plate. Does anyone has any good resources or links where I can get some info in trouble shooting this problem.
Hi I take it you get a square hole with some round indentation in one or more of the sides.
Possibly the hole was drilled 9/16", so the drill cut oversize, or you lined up the hole badly and the punch drifted to the side due to lack of support in the hole.
If the holes are already in the plate you've got problems, otherwise drill the holes to 17/32".
I've used a punch on a job like this before that had a small pilot on the end.