STEP 2

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.

 DRILLING HOLES and INSTALLING THE SWITCHES
 
  • 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.

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