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Getting leaf buttons into 1-1/8" metal CP hole?

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whammoed:

The kind I have are the draw stud type like in the second picture.  You drill a pilot hole, assemble the punch through it, and tighten the draw stud bolt till the hole is punched.
Here is an auction for one, it does include the draw stud, although it isn't in the picture.
http://cgi.ebay.com/greenlee-730-radio-chassis-punch-1-3-16-like-new_W0QQitemZ7587954363QQcategoryZ73116QQrdZ1QQcmdZViewItem

quarterback:

After much internal debate about buying new translucent buttons and ponyboy's new leaf-switches, I decided to take a whack at my CP.

I went out and bought a $5.99 rounded metal file and went to work.  I didn't have the 30-seconds luck that Stingray seemed to have, but after about 20-minutes of filing I was able to fit one my leaf buttons into one of the CP's holes.   Since it was much work, I decided I'd try the dremel... well, I had the same misfortune as Level42  and scratched up my new CP :(    It's not terrible, but it put me off the dremel idea, particularly since it didn't seem to be doing enough anyway.

So I went back to work with the file.  About 30+ minutes later I had two more of my CP's holes widened enough to fit my translucent leafs.    I took a break for about an hour, because my arm was getting sore, and then came back and did the three holes on the other CP.

I used the dremel to 'smooth' out the holes and take care of any little burrs and, sure enough, it hopped out and scuffed up my second CP as well.  ARRGHGHH!   Actually, neither scratch is terrible, but they're annoying nonetheless. 

In any case, the translucents are in the CP!   I still have to figure out exactly how I'm going to light them.  I'm not sure if I'm going to do the full-on Kneivel method because I'd like to get the thing built, but we'll see...

lkench:

This might be a "duh" observation, but to avoid scratching the top of a control panel, why not just turn it upside down and do the grinding/trimming/etc from the backside?  That way if you slip, you just slip onto the part no one ever sees.

-lkench

whammoed:


--- Quote from: lkench on February 11, 2006, 10:30:24 pm ---This might be a "duh" observation, but to avoid scratching the top of a control panel, why not just turn it upside down and do the grinding/trimming/etc from the backside?  That way if you slip, you just slip onto the part no one ever sees.

-lkench

--- End quote ---

Well, its too late now regardless. :-\  qb, I had a couple imperfect panels before too, I just gave them a misting of spray paint and they were good as new.  Do you think that is a possibility here?

quarterback:

Absolutely, to both previous posts :)

Yeah, I could have done them from the bottom side, but the 'rough' edges would be on the wrong side.  I mean, I'm sure I could smooth them out, but I filed/dremmeled from the top->down because it made for a smoother top side.

And, yeah, whammoed is right. I can probably 'mist' the top with a bit of black spray paint to cover up my imperfections.   And, actually, I have some of the parts-express 'vinyl' that I have contemplated as a backup solution.  I mean, I can always cover my previously-virginal-powdercoated-steel cps with some kind of more resistant covering.  It's not a huge deal,  I just wish I hadn't messed them up in the first place.

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