What's the best way/tool to cut or drill holes 1/8 inch to 5/16 inch in
diameter in thin gauge aluminum (for inserting potentiometers and
phono, power jacks, etc.)? I've tried using just a power drill and
genernal purpose drill bits and the results have been sort of ragged
(the edges of the hole are ragged and the process of drilling creates a
depression surrounding the drilled hole).

Buy a good set of Greenlee punches - they'll cost a bundle but
there's no other good way to do it.


I don't think I have ever seen a Greenlee punch for a hole that is only 1/8
of an inch in diameter. Most of the holes for the bolts I have seen are
much bigger than that.

To drill small holes you can get or grind your own bits. They will have a
point on them and be something like the spade wood bits. Also take a piece
of scrap wood and put behind the aluminum.