YDKJ, Drilling Pushbuttons

[SteveJ34]

I've finally got all my parts in for this project. I went with the shallow happ buttons suggested by Sasquatch based on the depth of the box.

I'm planning to make the hand buzzers using chopper bicycle grips, the same shallow pushbuttons (they fit nice and snug) and a piece of 1/2" PVC inserted down in the handle to firm up the inside.

My question is.....

What should I use to drill the holes in what appears to be like 1/16" aluminum plate on the control box for the pushbuttons?

Historically I have done all my panels and button mounting projects in wood so other than small holes I have drilled in metal and aluminum strips for trim/framing in some marquee sign projects, I'm  not completely sure what would be best for this so I don't screw the panel or the bits I have onhand.

These shallow pushbuttons are stated as being .93" diameter which  is a bit larger than 7/8" so I guess I will have to go with 1" bit.

I look forward to any and all replies.

Steve

[hiperco]

How about a chassis punch?  (Not cheap though).

If it is aluminum, a hole saw, lubrication, and lots of elbow grease might work.

Try googling "chassis punch", lots of info there.

[kcoleman]

I think you can get bimetal hole saws that should be able to drill through the aluminum. It would be easier if you have a drill press but if not you will have to use a variable speed drill, tightly clamp the piece and go slow.

[Trimoor]

I used a hole saw in 1/16" aluminum with no lubricant and had no problems.  Make sure you use a decent saw though.

[SteveJ34]

Thanks for the replies, gentlemen.

I was expecting that a hole saw would probably get the job done. The material is pretty thin so this shouldn't prove to be that difficult. Clamping the piece tightly so it doesn't take off on me when the hole saw starts to grab is a smart suggestion.

I appreciate the input and hopefully will have a pic or two to post after a little weekend activity.