Best way to make pushbutton holes larger?

[dailygeek]

Hi folks

Just converting my first JAMMA cab and so far so good.  Except that I ordered some new Happ pushbuttons from ultimarc, fully expecting my current buttons to be a standard size but when trying to replace my first one, realised that the diameter of the existing buttons is a couple of mm smaller than Happs.

What is the easiest way of making these holes big enough?  Hole drill bit through lexan and board or perhaps sanding around the edges.  Useless with woodwork which is why i'm converting rather than scratch building .... 

[clickhea]

iam gonna have to nominate the router for this job.

[nuka1195]

drill with a sanding drum.

[TheShanMan]

Or file it with a rounded wood file.

[DeLuSioNal29]

Dremmel.

[Kevin Mullins]

Hammer.

[fatfingers]

Router.

[um3k]

Clamp another piece of scrap over the hole.   Mark the center of the hole on the scrap and use your favorite forstner/spade bit.

[Malenko]

wood or metal?

dremel either way, just use either a grinder bit or a sander bit

[Xiaou2]

 Dremels stink.   Dont even bother with them.   You would use like 10 little sanding
drums, and it would take about 4hrs to do.

 I 2nd the drill + sanding drum.

 Of course, if you really want fast results,  they sell a special type of drum
made of metal.  It shaves wood like hot butter... and outlast sandpaper drums
by miles.

[Xiaou2]

 


 Microplane drums.  1" diameter is $10.99 at woodcraft.

[Blanka]

Is it metal or wood. If wood, you might have succes with a regular spade bit if you put a dummy sheet underneath to put the center pin in.

[dailygeek]

wood with lexan on top.

[Malenko]

Dremels stink.   Dont even bother with them.   You would use like 10 little sanding
drums, and it would take about 4hrs to do.

10 sanding drums and 4 hours for a couple of millimeters?  perhaps your technique differs from mine but I made 16 button holes and 2 joystick holes a couple millimeters bigger in about 20 minutes using 1 sanding drum.

[mountain]

I would probably cut the correct hole size in a piece of scrap MDF and center it over the existing hole using carpet tape. Then whip out the router with a flush cutting bit and open it up that way.

Or use a 1/2 round file.

[saint]

I would put a proper size hole in a piece of scrap wood, then clamp the scrap wood over the control panel with the holes properly lined up, then use a Fostner's bit. I would think that would work perfectly.

[Franco B]

I would probably cut the correct hole size in a piece of scrap MDF and center it over the existing hole using carpet tape. Then whip out the router with a flush cutting bit and open it up that way.

2nd'd

[Jack Burton]

Hi folks

Just converting my first JAMMA cab and so far so good. 

How many buttons are we talking about?  If it's less than 8 and only a couple of millimeters I would just get out a file.  I filed out the holes on a wooden panel with 14 buttons in less than an hour.  If you take you time and watch carefully the holes will still be "perfectly" circular, and the lip on the button will hide any mistakes you made.

[pmilnes]

Hell, you should do it the American way:

Step one - try to use the existing hole, since most people won't notice the difference.

Submit it for an RFQ, get bids from a MINIMUM of three vendors, then compare quotes.  Once you get the quotes, beat up your prospective vendors for a lower price.  Threaten to outsource to Mexico.  Then, outsource to Mexico.  When Mexico proves over time to be too expensive, outsource to China.  You are compromising on quality with China, but it looks good on paper.  Tell anyone that notices drop in quality that your specifications were clear, and any quality drop is justified by the additional savings.  Get a promotion based on the cost savings before your bad business decisions are noticed and catch up to you.

[ahofle]

I would put a proper size hole in a piece of scrap wood, then clamp the scrap wood over the control panel with the holes properly lined up, then use a Fostner's bit. I would think that would work perfectly.

Ding ding ding ding!
This should also work with a hole saw bit, and maybe even a spade?

[_Iz-]

I would put a proper size hole in a piece of scrap wood, then clamp the scrap wood over the control panel with the holes properly lined up, then use a Fostner's bit. I would think that would work perfectly.

Ding ding ding ding!
This should also work with a hole saw bit, and maybe even a spade?

I like the router + template idea the best. It might work with a holesaw but it's an invitation to disaster to try it with a spade bit.