First of all, I made this at TechShop Detroit. All of the tools used can be found in the shop, which is pretty awesome. The link for techshop is here:
I am building a guitar amplifier from a kit, and the motherboard was made of cheesy cardboard. I decided to make mine out of phenolic. This is one of my favorite materials to work with because is is easy to machine, and it looks beautiful. In this instructable, I will run through the steps for laying out the new motherboard and drilling/cutting it out. The phenolic I am using was salvaged from an old transformer. (Recycling... Yay!)
Step 1: Mark with a Scribe
The first thing I did was mark the edges of the template using a scribe.
Step 2: Check the hole size
The next thing I did was determine the size of the holes I needed using a caliper. I checked the size of the bit I was using against the template.
Step 3: Mark the Holes with a Transfer Punch
After clamping the template to the phenolic, I began to mark where my holes will be. Transfer punches come in many different sizes (they can be seen in the foreground of this picture.) They allow a person to transfer a mark to the new material in the exact center of the template holes. The also aid in making precise holes with a drill because it gives a drill bit a place to register. This prevents the bit from "walking" on the surface of the material.
Using a ball-peen hammer and light blows, I tap the transfer punch, making a mark on my new piece.
Step 4: Off to the Drill Press
After having all of my new marks made, Its time to make the holes with the drill-press. I simply line up the bit with my marks made with the transfer punch, and drill through the phenolic.
Step 5: Cut it out on the BandSaw
After drilling all the new holes, its time to take the piece to the bandsaw to cut out the final shape.
I used a push-stick to help move the piece through the blade.