heartben wrote:Howdy partners!
I am ordering a little diy kit and I need to order an enclosure. I have not had to drill one so I am kind of curious how people get their stuff set up so perfect. I mean... I don't really mind if mine is a little off or whatever but I still wonder. Printing templates or something?
Next! Bit sizes? All standard stuff. I need to know the size for pots/ footswitch/led/jacks/ac
God damn i have to buy a lot of drill bits.
Also I doubt the people who would be most interested will see this - but I am thinking of ordering extra boxes to fancy up for people to buy for their own projects. If you are genuinely interested let me know so I DO get a couple extra.
As always, thanks a bunch guys!
To echo a few other answers:
Drill press. The cheap ones are fine, but the cheap one at Harbor Freight is a bit too small to drill the sides of a BB enclosure with standard drill bits (at least the big ones for jacks and such). Fortunately, they sell a step bit that's perfect. But the I've had bad luck with their bigger step bits... they seem to just stop working. But the 1/8"-1/2" one is fine.
I use some cutting fluid I got from Smallbear. It's fantastic, and the step bits never gum up if I use it. If you don't use it, they can gum up with aluminum and you'd have to scrape them out. I've never worn one out, but you'd think they're dead if they gum up enough. Aluminum is just like that. It can happen with regular drill bits too, but they're not as bad about it.
For templates, there's lots of options. You can find (or make) a paper template, or if you're handy you can make a box out of wood or metal that sits over the pedal and has holes in it. Or, just measure and mark the enclosure carefully. A small combination square is pretty swell for getting even marks from the edge of the enclosure, and a spring-loaded center punch (aka "machinists punch") is great for marking making a little hole in the enclosure so the drill bit doesn't walk. Everyone kinda has their own way of doing this stuff, it seems. I'm sure other DIY forums have tons of info as well. Buy an extra enclosure or two just in case.
Drill sizes! (based on the standard step bit, because that's what I use)
3mm LED: 1/8"
5mm LED: 3/15 for a tight fit (where the LED doesn't go all the way through), 7/32 to clear, although I think 13/64 might be better.
Toggle switch: 1/4"
Pot: 9/32"
1/4" Jack: 3/8"
DC jack (the most common one): 1/2"
Footswitch: 1/2" (although some are really 15/32", but who cares?)
Things like switches, pots, and jacks can be drilled slightly larger and be fine. For instance, you could just get a 9/32" drill bit and use it for pots and toggles.
I never use clamps to hold the enclosure, but apparently you should. You should also wear safety glasses. You coward.
Too slow of a drill speed makes less nice holes, and too fast makes too much heat and increases the chance of snags. I usually drill on the second lowest speed of my drill press, which is 900 RPM. Sometimes I slow it down. For drilling a bunch of small holes (like pilot holes), I speed it up. Usually to the top. Because the sound amuses me.
.... rock? ROCK!
