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Step 3Drilling and Cutting
Short version:
Cover in masking tape, mark hole locations, drill pilot holes, drill appropriate sized holes using pilots as reference.
Long version:
I did the layout freehand, marking the middle of the box using the square, and just measuring and sizing up locations using the components. To make it easier to write on the box, cover it in masking tape. Use a sharp pencil so that you can get accurate markings and can erase if you make a mistake. Take your time and get it right, theres no turning back once you start drilling.
Use a 1/8" or 3/32" drill bit to drill pilot holes at each hole marking. For the IEC connector hole, drill in each corner of the rectangle.
After I drilled pilot holes in the corners I used a 1/4" bit to drill around the perimeter of the rectangle, being careful to not pass over the edges. Then, I used some pliers to snap the remaining plastic out of the center, and used the flat file to file it into a rough rectangle. Keep filing and test fitting the connector until it fits snugly. Be careful with IEC connectors that have pop-out flanges to lock them in place, since those are most likely designed for metal enclosures and thick plastic may prevent them from locking in place. I had to switch for a connector that had mounting screws because of this. Once the connector is in place, you can drill holes for screws or bolts/nuts with no problems.
The rest of the holes will need to be drilled appropriate to the bolts you've selected for mounting your transformer and the diameter of your capacitors. My capacitors were 30mm diameter, so a 1 1/4" drill (about 32.5mm) worked great. The diameter of most DC jacks is about 8mm, but check with a vernier before you drill.
The aluminum plate that goes over the DC jacks is 4" long by 1" wide. I used a 5/16" drill bit for the holes on it, spaced 5/8" apart. You can use the bastard file to remove the sharp corners, and some 120 grit sandpaper to smooth the edges and give it a brushed look. I used 4.40 threaded hex head screws to secure it in place.
Cover in masking tape, mark hole locations, drill pilot holes, drill appropriate sized holes using pilots as reference.
Long version:
I did the layout freehand, marking the middle of the box using the square, and just measuring and sizing up locations using the components. To make it easier to write on the box, cover it in masking tape. Use a sharp pencil so that you can get accurate markings and can erase if you make a mistake. Take your time and get it right, theres no turning back once you start drilling.
Use a 1/8" or 3/32" drill bit to drill pilot holes at each hole marking. For the IEC connector hole, drill in each corner of the rectangle.
After I drilled pilot holes in the corners I used a 1/4" bit to drill around the perimeter of the rectangle, being careful to not pass over the edges. Then, I used some pliers to snap the remaining plastic out of the center, and used the flat file to file it into a rough rectangle. Keep filing and test fitting the connector until it fits snugly. Be careful with IEC connectors that have pop-out flanges to lock them in place, since those are most likely designed for metal enclosures and thick plastic may prevent them from locking in place. I had to switch for a connector that had mounting screws because of this. Once the connector is in place, you can drill holes for screws or bolts/nuts with no problems.
The rest of the holes will need to be drilled appropriate to the bolts you've selected for mounting your transformer and the diameter of your capacitors. My capacitors were 30mm diameter, so a 1 1/4" drill (about 32.5mm) worked great. The diameter of most DC jacks is about 8mm, but check with a vernier before you drill.
The aluminum plate that goes over the DC jacks is 4" long by 1" wide. I used a 5/16" drill bit for the holes on it, spaced 5/8" apart. You can use the bastard file to remove the sharp corners, and some 120 grit sandpaper to smooth the edges and give it a brushed look. I used 4.40 threaded hex head screws to secure it in place.
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