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Drilling Holes in Holey Metal

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leapinlew:


--- Quote from: Necro on July 28, 2011, 11:29:47 am ---
--- Quote from: gryhnd on July 27, 2011, 07:30:52 pm ---Agreed. Works well. I did the same thing when I needed to widen the holes in an old TV cabinet:

--- End quote ---

The problem is 'm cutting through steel and it requires cutting oil...if it was wood, it would be fine. (see what I did there)

--- End quote ---

Cutting oil? How thick is the metal on this control panel? I think you are making much more work out of this than you have to. I've cut through plenty of metal CP's with predrilled. here is the process I took:

1. I clamped a piece of wood on the bottom and I used bondo to repair the holes.
2. I cut the control panel I wanted out of 3/4 MDF or Plywood. The control panel was cut to size.
3. I clamped the finished wood control panel top to the metal CP that has been repaired with bondo and still has the bottom piece of wood forming a sandwich.
4. I used a sharp hole saw to cut out the button holes/joystick holes. Once it cut the metal, I moved on to the next hole.

Honestly, after the bondo repair, you probably don't even need to have the wood jig. I've done it both ways with success.

Screw the oil. You'll be fine.

Nephasth:


--- Quote from: leapinlew on July 28, 2011, 11:48:58 am ---Screw the oil. You'll be fine.

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+1 I've only had to use cutting oil when drilling through THICK metal (3/4"+). I have also found that using paint thinner for a drilling lubricant kept the bits cooler and allowed them to cut easier than when using oil (I only use lubricant when drilling a lot holes in one session).

Necro:

2" Plate Steel.  Why...that's not normal?  :)

And just kidding - it's about 1-2mm thick steel.  A metal drill bit goes through it decently, but I'm more worried about the hole saw as I need to cut...a LOT of holes as I'm doing 3 swappable panels.  Also, I thought the bondo wouldn't hold the pilot bit in place.  Never used it before.

I'll know rather quickly after drilling the first hole whats needed I guess.

Necro:

Well - I drilled one panel.  Did all 1-1/8" holes with the hole saw and the 5/8" holes (for cone buttons) with a step bit.  Overall, I actually like the holes the step bit makes much more.  MUCH cleaner, less 'chatter', etc.  But, I can't see the bits I got lasting for 3 panels so I went with the hole saw.  The holes are not 'perfect' - i.e., the alignment is 100% perfect - but for something I did by hand myself on a drill press I think it's good.  Only one hole/button may have an issue and need some 'structural support' added so the button doesn't slide.  Oh, and two empty button holes are going to get the washer/JB weld treatment just for structure/ensuring the art doesn't get ripped.

In case anyone's wondering, I used an 1/4 inch hard board overlay to align the holes, get things setup, and get the hole saw aligned (from the top).  I used wood supports under the panel and drilled into it when necesary, but having it behind the metal didn't actually do much aside from provide support.  Also, cutting oil 100% helped the cutting.  I even put it into the 1/4" hard board holes to assist there.  Should keep the blade sharp longer and usuable for all the cutting I need to do.

Thanks again all for the help/advice!

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