Drilling in a curved metal surface

[joelwideqvist]

Hi
I'm going to use the meter below in one of my builds.



To install it I need to drill a 1,5 or 2 mm wide hole in the side wall. So how to do it? I ask as I have not drilled in metal before and certainly not in a piece this small and with a rounded surface.

I guess I need some drill bits for metal but can you actually do the drilling in a curved surface without a drill board and a milling machine? As you can guess I will not invest in such a tool just for this purpose so I need some input if it can be done without. Or shall I just go and find some person who has the proper tools?

Any hints on where to find micro drills for metal? I also need to drill a .5 mm hole for the wiring...

Best regards
Joel

[klutz_100]

What I have done is to use a sharp sewing pin or needle to make a small starting mark in the soft metal as a guide point and then held the part in place with pliers and used a pin vice to drill the hole. HTH

[joelwideqvist]

Thanks for your quick reply Klutz! Are you using any special drill bits?

[cinqster]

I've have 3 or 4 of these packs and they are the only small drill bits I use. They're perfect for what you are after and relatively cheap. They're also available at most model shops across the UK:

http://cgi.ebay.co.uk/20piece-HSS-TW..._PowerTools_SM

John

[klutz_100]

Originally Posted by joelwideqvist

Are you using any special drill bits?

No. Actually, I am using pretty much the same kind that John gives the link to.

[joelwideqvist]

Great, thanks both of you!
/joel

[MPWR]

Aluminum is certainly not hard to drill by hand. It is a soft, easily worked metal (compared to steel and 'exotics'). Be careful holding the part in pliers- you will very easily damage the aluminum if holding it in steel pliers. Use something soft to pad the jaws of the pliers.

Any small drill bit you have will drill aluminum. HSS stands for "high speed steel", which is a strong, hard steel alloy that cutting tools are made of. It is the most common material that small drill bits are made of. It works very well for drilling aluminum, either in power tools or in a pin vise. So if you already have small drill bits for plastic, they will work fine.

Drilling by hand will take care and patience, but it is definitely possible, and it is a reasonable solution to your problem.

[MidMazar]

Originally Posted by klutz_100

What I have done is to use a sharp sewing pin or needle to make a small starting mark in the soft metal as a guide point and then held the part in place with pliers and used a pin vice to drill the hole. HTH

Percisely, you have to make a dent. Or else your drill bit is going to be moving around.

Try www.Micromark.com
They have tons of neat stuff to chose from. A lot of different drill bits for a decent price.

[joelwideqvist]

Thanks MPWR for sorting the drill issue out and for the heads up on the pliers.
Thanks also to you MidMazar for the link!
/J

[cinqster]

Originally Posted by joelwideqvist

Thanks MPWR for sorting the drill issue out and for the heads up on the pliers.
Thanks also to you MidMazar for the link!
/J

It's often handy to tape up (cover) the model part itself rather that the tool, to protect it. This has become second nature for me when using the lathe. I cover small machined parts in ordinary 3/4" plastic insulation tape cut to size. One layer is enough for protection if you are careful. For a lathe you have the added problems of having to get the layers even, otherwise the piece will turn eccentrically.

[klutz_100]

J, since we are managing to turn your little simple into an encyclopaedic thread, I'd also have to warn you that in all probability, if you will be wiring the dial, you will be drilling a very small diam hole and therefore using a very thin drill bit - and they snap at the slightest excuse

Be careful, try to maintain a perfect right angle to the piece you are drilling and don't be tempted to use one of those (otherwise very cool) spring loaded Archimedes-type pin vices. Stick with a simple drill vice and go slowly without excess pressure.

[Decs0105]

Originally Posted by klutz_100

...don't be tempted to use one of those (otherwise very cool) spring loaded Archimedes-type pin vices. Stick with a simple drill vice and go slowly without excess pressure.

Wow that thing looks cool, although very dangerous for small, little helpless drill bits

Originally Posted by MidMazar

Percisely, you have to make a dent. Or else your drill bit is going to be moving around.

I got a set of center punches like this LittleMachineShop, really handy when you work with metal. But if you just drill one hole a year you are probably better of with Klutz's idea.

Joel it is also a very good idea to buy atleast 2 from the smaller drill bits since they will always break either on Saturday afternoon or Sunday which means no more modelling for the weekend

[stainlesssteel]

Well a good method (and the one I use) is to sand the part flat...not the whole part...just the area you want the hole...no one will notice that you sanded it...Good luck

[Didymus]

With a file, sharpen a nail or long screw to a point. Make a "handle" with tape or a rag. This home-made awl will make a good hole starter. If you're working with hard metal that you can hold in a vise, tap it with a small hammer to help make a deep-enough hole.

I'm working on a white metal model that has long rows of rivets. I had to drill a hole for each rivet. To start the holes, I used a drafting divider that has a sharp pin in each leg. The divider didn't only space the holes, it actually started them.

[joelwideqvist]

Thanks a million for all your tips, they are most appreciated!
/J