Turn a generic plastic gadget in to something a little more beautiful

Step 4 Faceplate 2: Cut out holes for switches & display

This is a great example of where the design can change in the course of the build. I originally put the clock display to the upper left in the sketches. As I laid out the switches according to the original design it became clear that placing the clock display in the center was going to work out better.
I marked up a new layout with a felt pen on the faceplate that centers the clock display, it had a much nicer feel to it. Never be afraid to change course in mid-build but always double check any change against the original design... there might be a reason you did something a particular way.

Drilling the holes for the switches (part 1)


Drilling the holes for the switches (part 2; close up with safety tips)

And yes, the holes were still a tad too small and I had to use the next bit size up. Better safe than sorry!

Round holes done, now on to the square holes...
Next up are the square holes for the seven segment clock display & alarm on/off button. I am more of a woodworker than metalsmith so I'm happy to hear suggestions on a better way to cut square holes in metal. I chose to use my scroll saw and it worked out pretty well. I was able to finish the job off with a flat file.

Cutting out the square holes for the clock display & alarm on/off button: part 1


Cutting out the square holes for the clock display & alarm on/off button: part 2


I love the way the video capture rate of my camera is just out of sync with the scroll saw and gives the impression the saw blade is only barely moving up & down

References
Drill bit sets from Sears
Compass from Sears
Bench vise from Craftsman