On Sat, 31 Jan 2004 20:46:26 -0800, Paul Clay
wrote:

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 drill press will hold the drill much more steadily for cleaner
holes. Not always available, though.

There are various things which you can attach to a hand drill to get
much of that steadiness, kind of a ring plate with two rods that the
drill rides on. You could even clamp this on to your piece to get the
equivalant of drill press accuracy.

Marking the hole with a center punch is very helpful.

You will do better with a hand drill by using a pilot hole, then up to
the actual size you want. Step drills are another way to do this, and
work quite well.

An aluminum cutting fluid will help.

When drilling, patience is important. Let the drill speed do the work,
not the drill power or downward pressure. Forcing the drill will
create the raggedness.

You will also do better with specialty sheet metal drills, rather than
general purpose. Sharper is better. The TiN coated ones will stay
sharper longer.

For square holes, a metal nibbling tool is ideal.

As for labels, there are many types of clear labels which a laser
printer will print on, the inkjet ones can smear. Artist's fixative
spray will help.

Also look at things like the Brother P-Touch label maker, especially
the ones which attach to a PC.

Happy trails,
Gary (net.yogi.bear)
------------------------------------------------
at the 51st percentile of ursine intelligence

Gary D. Schwartz, Needham, MA, USA
Please reply to: garyDOTschwartzATpoboxDOTcom