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Step 6Drill the Component Holes
This step can easily destroy all your hard work so far, so do it carefully.
Previously we drilled three pilot holes in the plastic. Flip the case over so you can see them from the inside. Some glue may have squidged through the holes - yank it out now. Find the correct size drill bits for the components you're mounting. In my case, the switch was 1/2" and the potentiometers were 5/32". I used regular drill bits, not Brad point or Forster.
It's very easy to tear up the veneer, splinter the plastic, or rip apart the aluminum duct tape if you drill improperly. Drill from the inside of the case* using the pilot holes to help align the bit. The key here is to go very slowly, clearing away debris, and prevent the case from moving while pressing it firmly onto a scrap piece of wood. It would probably be a tremendously bad idea to use anything other than a drill press for this task. You've been warned.
Watch as the bit cuts through the various layers and adjust your speed accordingly. If at any point you can't see what you're doing, stop and clear away any debris. When you get to the veneer layer, go very very slow to avoid tearing it. The veneer's bond to the plastic is OK, but it's not as strong as if it were glued to wood.
Hopefully, you'll end up with nice, clean holes. Hopefully, you won't have to do repairs or start over...
Previously we drilled three pilot holes in the plastic. Flip the case over so you can see them from the inside. Some glue may have squidged through the holes - yank it out now. Find the correct size drill bits for the components you're mounting. In my case, the switch was 1/2" and the potentiometers were 5/32". I used regular drill bits, not Brad point or Forster.
It's very easy to tear up the veneer, splinter the plastic, or rip apart the aluminum duct tape if you drill improperly. Drill from the inside of the case* using the pilot holes to help align the bit. The key here is to go very slowly, clearing away debris, and prevent the case from moving while pressing it firmly onto a scrap piece of wood. It would probably be a tremendously bad idea to use anything other than a drill press for this task. You've been warned.
Watch as the bit cuts through the various layers and adjust your speed accordingly. If at any point you can't see what you're doing, stop and clear away any debris. When you get to the veneer layer, go very very slow to avoid tearing it. The veneer's bond to the plastic is OK, but it's not as strong as if it were glued to wood.
Hopefully, you'll end up with nice, clean holes. Hopefully, you won't have to do repairs or start over...
- One thing that I ought to have tried is drilling the pilot hole through the veneer, then drilling the larger holes from the veneer side. Feel free to make a test piece to try it this way, and be sure to let me know if it works!
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