Paul Clay wrote in message ...
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).

What's a good technique for labeling front panel controls on a piece of
homebrew gear? Are there self adhesive labels or decals that
stick/wear really well?

Tnx!

A big question, but briefly.

1.Buy sheet metal drills - might be worth it if you are only looking
at 2-3 sizes.
2.With ordinary drills, use a backing board to stop the flared effect.
Start with a small size and work up in 64ths till you get the desired
size. Tedious, but works.
3.Buy a tapered reamer, and use it to widen a say, 0.25inch hole. Ream
from both sides, needs a bit of practice. Clean up edges with a bunny
knife.

For labels:-
1.The new DYMO labelling guns are good - much better than the old
embossed plastic ones - its a thermal printing sustem, works well.
2.Do your arwork on good quality paper to size, print it out, trim to
size, stick to front panel with clear self adhesice contact film. (Its
called "contact" here in VK, may be the same there, dont know.) A bit
of stuffing around, but worth it.
3. Buy a lettering template and draw directly on the aluminium with a
say 1mm overhead projector trnasparency pen. looks ok, then spray with
clear lacqer.

Dont be too hung up on what it looks like, it can get in the way of
actually getting a project on air - and besides, the person at the
other end of the QSO wont know anyway!.

73 de VK3BFA Andrew