[iriverdude]

Quote:

And using a Dremel and claiming the final hole is perfectly round...

Hands of a android? I guess if he's putting a flange around the imperfect hole, it doesn't need to be perfect to +/- 1mm

 

[nickyboyo]

John, i could put the holes in at work for you, or let me know dimensions etc and i will see if i can find the tooling for you to borrow and you can do the job yourself.

 

[Nisbeth]

I've used a stepped drill and drilled from the back on the Galaxy cases and gotten good results. Use a drill press if at all possible, otherwise be sure to clamp the panel securely in place. Use alcohol for lubrication (of the drill, not yourself

)


/U.

 

[MoodySteve]

There is no substitute for good machining equipment.

For perfect holes in sufficiently thin metal, my preferred method is punching, but you need the punch and tooling. After that, I would say the best method would be milling. I haven't had as much luck with plasma and laser cutting, plus milling is not sensitive to the alloy/composition of your metal.

A stepped bit is probably the most reasonable approach if you're going to DIY, but I'd see if I could have the work done before going that route. If you end up going the DIY route, make sure you have a good way of securing your panel so it doesn't move.

 

[iriverdude]

Quote:

securing your panel so it doesn't move

or jam :-D


http://www.youtube.com/watch?v=bpaE3IQD8bM

 

[tenzip]

Quote:

Originally Posted by iriverdude /img/forum/go_quote.gif or jam :-D YouTube - gromit drilling

Gromit FTW!

 

[Uncle Erik]

Try finding a used chassis punch on eBay. I've picked up an assortment of Greenlee punches over the years and they make the cleanest holes.

I've also had luck using a hole saw which makes a pretty ugly hole. However, it is fast and they clean up nicely with a wide, rounded file.

Be sure to pick up a few files and sandpaper, too. Hand files are the easiest way to clean up a hole and make it smooth. Sandpaper takes off rough edges and makes it soft to the touch.

 

[kklee]

Quote:

Originally Posted by Uncle Erik /img/forum/go_quote.gif I've also had luck using a hole saw which makes a pretty ugly hole. However, it is fast and they clean up nicely with a wide, rounded file.

I found that clamping a piece of wood under the piece you're working on helps a lot with making a clean hole using a hole saw. A couple of drops of oil while you're drilling helps as well.

 

[dbfreak]

I use the Lenox Bi-metal hole saws on my drill press. The technique is to apply just a light to moderate amount of down-force and use a cutting oil. Works for me everytime (also an excellent way to make holes in acrylic/plexiglass).

 

[Tightwad]

I prefer the step drill, but not in a drill press (it chatters too much). Do it by hand slowley. Not sure on big sizes, but i would use the most steps possible, and go slow. To avoid slivers, drill from both sides to cleanup, then run a razor blade over the edges to clean them.

 

[dBel84]

"hand file" to all you ninnies, perfect round holes to go with the padded walls

..dB