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).

Hi.
I've read a very cool suggestion somewhere (GQRP's list perhaps) for
drilling clean holes in Altoids boxes (therefore all aluminium boxes):
fill the box with water, freeze it, then drill.

I usually start with 3mm bit for metal, then 4mm, 5mm and increasing in
small steps. Having a general purpose drill with linearly variable speed
helps too.

Cheap but somehow slow :-)

HTH,
Paolo ZYW

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