Wiardgroup

Hi doc,

I'm not Les, but I have a suggestion for one of your questions. In 
the electrical department at HomeDepot and other hardware stores you 
will find step drills. These Christmas-tree-shaped bits will easily 
drill holes up to 1-3/8 in ammo box steel, synth panel or housing. 

Two sizes of bits needed to get to that size hole. The larger one is 
not as commonly useful, going from 7/8 to 1-3/8 by 1/16". A typical 
smaller step drill bit goes from 3/16" to 7/8" in 1/16" steps; 
another goes from 1/8 to 3/4 by 16ths. Either of these latter two is 
a good candidate for SDIY use. About $20-25. It is very easy to use 
the next step to deburr all holes drilled  except the largest, where 
there is no larger next step to use!

Drill the small hole 3/16 or 1/8 using a regular drill bit (a screw 
machine length 135° split point will work best) and then open it up 
with the step drill. Works REALLY well, and the holes stay concentric 
with your pilot; something which doesn't always happen using 
successive twist drill bits.   

Kind regards Randal

--- In wiardgroup@yahoogroups.com, "drmabuce" <drmabuce@...> wrote:
>Most connector diameters are beyond the range of hardware-store drill
>bits, and they don't like chewing through steel, anyway
>....How did you cut your large diameter mounting holes? a die cutter,
>perhaps? 
>enquiring minds want to know!
> ;'>
> 
> thx,
> -doc
>