A simple warning. Drilling sheet metal tends to act like a thread,
the exact moment the bit goes though. The work piece will crawl up
the bit and spin out of control. The Drill bit can also thread
its way though forcing the sharp bit into something you don't want
drilled, like your hand. I drilled though an expensive, brand
new radiator by doing this. Don't get too excited and get in
a hurry. Some shortcuts are not worth taking. DO
NOT hold the bay cover with your hands.
You should place the bay cover in a
vise, clamped, but not clamped too hard as to bend your work.
Sometimes I use bowlers rosin available at any bowling alley, to
increase the grip strength, without have to clamp down the vise
so hard. Also backing up the work piece with a piece of wood
helps too. After drilling, de-burr the holes to avoid any
sharp edges. I used a de-burring tool available at any firearms
stores that sell reloading supplies. A Dremel too works too.
Just turn the speed down and don't get carried away, remember,
your
just de-burring.
|
- Attach the template you printed
(or your own).
- Punch each spot, where the hole
are to be drilled.
- Drill the pilot hole with the smaller
bit.
- Drill the 15/64 hole
- De-Burr the holes.
- Take the nuts & washers off
switches, except for the last nut.
- Throw the washers in your cool junk
box, you won't need these for this project.
- Stick the switch though the hole
and decide how much you want it to stick though.
- Keep adjusting this until you have
about 1 extra thread showing after the last nut is installed.
- Any problems keeping the nuts tight?
try your finger nail polish.
- Warm up your soldering iron.
- Start cutting speaker wires about
3" or 4" long, then part both ends slightly with a
utility knife.
- Strip both ends, Most computer devices
use really fine wire so you may have to strip double the length
and fold it over.
- Add your heat shrink tubing now,
it's your only chance to do so.
- I add the heat shrink tubing as
it' tends to stiffen up the wire, making the ends easier to find
when all this is buried in the case.
- Solder the wires to switches, then
crimp on the quick disconnects.
- Number the Quick Disconnects, 1
though 4 and the same on your devices.
- Tug on the disconnects to make sure
they are secure.
|