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Best way to make pushbutton holes larger?

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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:

--- Quote from: Xiaou2 on October 25, 2008, 08:47:40 pm --- Dremels stink.   Dont even bother with them.   You would use like 10 little sanding
drums, and it would take about 4hrs to do.

--- End quote ---

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.

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