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drilling new holes into a metal CP
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orion:

--- Quote from: Kevin Mullins on October 22, 2008, 04:36:21 pm ---quote author=Nemss316 link=topic=85881.msg901212#msg901212 date=1224705848]
My marquee and CP overlay are in,

--- End quote ---

He didn't say he put it ON.  :cheers:

As for the metal hole saw .... 1 1/8" is the correct finished hole size, but I personally recommend a 1 1/16" hole saw due to the fact that that kind of hole saw bit tends to "chatter" causing the hole size to be slightly larger than the bit is intended. Once it chatters the pilot hole will enlarge causing the bit to "walk" a little, once that happens the outer hole saw also walks.

[/quote]


I had this happen to me on the metal control panel that I drilled. The hole was so big that the happs buttons were to small for the hole. Luckily Willams leaf buttons fit just fine. All in all in my case I consider it a happy accident as I like the leaf buttons so much better than the microswitch ones. Also you will want to have some oil on hand to lubricate the hole saw periodically as you are drilling as it will get really hot and mess up the hole saw if you don't. Let the speed of the drill do the cutting, don't put to much force on it. I had no real problems drilling out the 1 1/8 inch holes but drilling out for the 3 inch trackball about burned up my drill and it can get away from you if you aren't careful.
More Cowbell:
Yeah, those tiny shards of metal get red hot. Then watch out for the hunk of metal that looks like a washer that falls out of the drill when you're done. Skin-charringly hot.
Franco B:
Lubrication ;)

Personally I would pre drill the hole and use a 1 1/8" slot drill/end mill but you may not have access to them.
Kevin Mullins:

--- Quote from: Franco B on October 23, 2008, 01:23:28 am ---Personally I would pre drill the hole and use a 1 1/8" slot drill/end mill but you may not have access to them.

--- End quote ---

Yeah, and with a two-flute end mill you don't even need to pre-drill .... but then again, you also kinda need a MILL.
 ;)
Franco B:
Slot drill = 2 fluted end mill ;)

True, you dont need to pre drill but I always do with thin material to stop it from wandering.

Yeah a milling m/c is kinda a must isnt it  :D Saying that I have used one in a radial arm drill with a handwheel.
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