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Metal CP - Rebuild and Redrill/punch?

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Namco:


--- Quote from: Necro on October 21, 2008, 04:51:47 pm ---I get the theory here, I guess what I'm not getting is how in the heck you get the circle saw to work right if say....you have to cut a circle where half it the circle is already gone - including where the center of the hole drill would go.  Make sense?  Basically, new hole overlaps an already existing hole.  (So basically step 3 below). 

And you can drill bondo with a spade bit without it obliterating/shattering itself?

--- End quote ---

When I did mine, there were many places where the underlying control panel had gaps and would not allow the placement of a pilot hole. In these cases, I inserted the hole saw through the hole and depressed the trigger to activate the drill. Because I bolted the new control panel to the top of the old one, I was able to use the new button holes as a guide to drill through to the old control panel.

To clarify:
1. Attach freshly drilled control panel to the top of the old one.
2. Observe gaps and holes.
3. Insert hole saw, pressing as far down as it can go.
4. Make sure to align the hole saw with the holes of the topmost control panel.
5. Squeeze the drill's trigger and hold the tool steady as it cuts through the metal.

Necro:

Ah, ok...that makes some sense.  I'm thinking of placing a piece of wood behind the CP also when doing this, providing a hard backing surface to drill into as well.

Well, I'm 99% sure I know how I'm making my CPs now.

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