Dotcomformat

I'd like to add a comment to Larry's good advice. First, I'm using 
6160 T1 1/8" aluminum sheets, a Dewalt hand drill, and various drill 
bits. I have never used a blank panel from Syn.com so these comments 
might not be valid (differing type of aluminum? Syn.com not as thick, 
etc.)
  All panel advice I've seen suggests starting holes small, then use 
progressively larger bits to arrive at the desired size. When I do 
this the drill jams up and tries to jump out of my hands. I have good 
luck by drilling every hole with a 3/16" bit (after using the hole 
punch, of course), then drill to the size I want (i.e.: 3/8" for a 
jack). I never jam up even with smaller holes. I'm guessing that a 
drillpress wouldn't have this problem ?






--- In dotcomformat@yahoogroups.com, Larry Hendry <hendrysr@y...> 
wrote:
> 
> I hope you have a drill press.  But, you can do it with a hand drill
> if you are very careful.  If using a hand drill BE SURE to clamp the
> work piece.  Otherwise, somewhere along the line the drill WILL jerk
> it out of your hand.
> 
> Go down to Lowes or a similar store and buy a center punch.  Get 
what
> is called an "automatic" punch.  You will pay $10 to $20 for it.  It
> will be your friend forever when drilling metal.  An automatic 
center
> punch is spring loaded so you just push it down and it clicks a
> dimple instead of having to hit it with a hammer.
> 
> DO NOT try to drill your panels without a center punch.  You will be
> sorry.
> 
> After I center punch, I cover the entire panel front with masking
> tape.  No need to press it onto the surface with vigor, just let it
> stick.  The I find my center punched holes and punch them again in
> the same spot through the masking tape.  Start out dilling all holes
> the same size with a bit smaller than 1/8"  Then you start using
> slightly larger bits until you get each hole the size it is supposed
> to be.  I write the holes sizes on my masking tapoe if they are
> smaller than 3/8" (jacks).  I use about 3 bit to get to 1/4"  The
> jump in 1/16ths after that.
> 
> As I move up in size, I drill each hole again.  When I get up to the
> size that a hole is supposed to be, I cover that hole with tape so
> when I go back and make the others bigger, I will not accidentially
> drill any holes too big.
> 
> After all holes are drilled, take a bit large than the holes, and
> drill from the back, just enough to clear up all the ragged edge.  
Be
> careful not to cut through.  This is easy with a drill press.  If
> using a hand drill, you may want to try something else.
> 
> When done drilling, peel off the masking tape.  If you do not use
> masking tape, you run a risk of scratching the panels with metal
> shavings from the drill bit.
> 
> hole sizes:
> T1 LED, no holder (Miniwave size) = 1/8"
> MOTM and dot com toggle switches 1/4"
> MOTM style LEDs 5/16"
> Dot com style pots 5/16"
> MOTM style pots 3/8"
> Jacks = 3/8"
> 
> Good luck, write if you need anything else.  Oh and one more thing. 
> DO NOT try to drill your panels without center punching every hole
> first.
> 
> Best,
> Larry
> 
> P.S. DO NOT try to drill your panels without center punching every
> hole first.
> 
> 
> 
> 		
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