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Drilling Holes in Holey Metal

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Necro:

Minor issue popped up when drilling my CP.  I'm using a previously used Omega Race panel and it has a few holes in it already.  Of course, a few line up EXACTLY with where I want to put button holes. This presents a problem in drilling out the 1-1/8" holes for the buttons as I have nothing to drill the 'centering' drill into OR the centering drillbit is going to wander because it's right on the edge of the existing hole.

Thoughts, ideas?  I'm debating tightly clamping everything in place and then 'free drilling' the 1-1/8" holes with just the hole saw (no guide bit) or having the guide bit go into a piece of wood below the metal.

Any other suggestions?

jimmy2x2x:

Sandwich the metal between 2 pieces of wood, clamp it all together then drill.



mgb:

I'm currently in the middle of building a metal control panel that has existing button holes but I want a different layout.
I first contemplated having the holes filled with metal slugs welded in.
I instead went the somewhat cheesy but cheaper way of using the knock out slugs from an electrical box (3/4" fitting).
I took the knock outs and roughed them up real good with a dremel tool cut off wheel. I removed the galvanizing from both sides of the knock out.
I also roughed up the metal of the control panel too. I placed the panel on a flat surface and placed the the knock outs in the unwanted holes and went over them with a skim coat of JB Weld. after those cured overnight, I did the same thing to the other side. you can then build them up as needed and skim coat the whole thing in bondo.


Necro:

Will JB Weld hold when you drill though?  And I thought bondo would just shatter if I were to use a hole or step drill on it. 

From a 'visuals' perspective, there's going to be art over it so I'm comfortable filling it/fixing the holes 'post' drill - it's more the getting it stable to drill. 

Also, 'sandwiching' with wood won't work - hole saws won't cut wood properly and if it did, I couldn't get the drill oil on it properly to actually cut the metal.   I'm thinking the 'half a sandwich (i.e., wood under' approach may be the best for the initial drilling, then 'repair/fill' where needed, and dremel out touch ups if necessary to ensure controls fit.  I guess... :/

It's never easy... :)

brad808:

Hopefully this makes sense to you....

What I have done before is cut a piece of wood the same size as the control panel. I then cut out the inside of the control panel so there was only an inch boarder around the outside. Then take the wood and route a one inch boarder in the wood the same thickness as the metal. This allows the wood and metal to sit flush.


This does require something to hold the wood in place, I used 4 carriage bolts in the corners, but the control panel I did this on was otherwise beyond repair. Pus it looks like the bolts are simply holding the plexiglass

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