Wiardgroup

Thank you, gentlemen
Golly my cup runneth over with tips from real-deal metal guys!
  50% of the time i work with plastic because i have a source for a 
lot of nice scrap material*. When i do work with metal (45%) i stick 
with aluminum because i can damn-near poke through it with a sharp 
fingernail. When i have to use steel (for strength or shielding) i 
lean on a friend who is a retired aerospace machinist with a 
basement full of scintilating tools. i just hate admitting to him 
that i need help with a simple round hole. When i 'recycled' some 
ammo boxes i was astonished (and so was my poor beleaguered Black & 
Decker) at how tough they were. Bravo Military-Industrial Complex!

and thank you all for the tips
-Doc

* i have a friend who builds mock-ups for Boeing with transparent 
sections. She uses a formulation of plexiglass that is highly 
resistant building-up static

don't let DIY die!
We need resistors we can touch
SAVE THE THROUGH-HOLE COMPONENTS
JOIN PDIPRESCUE!
(ok.... i'm being a smartass...there is no PDIPRESCUE....but there 
SHOULD be)


--- In wiardgroup@yahoogroups.com, "Gary Chang" <gchang@...> wrote:
>
> Doc,
> 
> actually (and not to be contrary, randal), I use a Greenlee die 
cutter
> - it places less stress on the overall structure (in this case, the
> corrugated metal box).  Was it a 15/16 inch that is the standard 
xlr
> size?  don't make me go find my dies, now!!!
> 
> gary
> 
> 
> 
> 
> "randaleem" <randaleem@> wrote:
> >
> > 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
> > >
> >
>