Metal Control Panel Drilling

ArcadeGeek

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So far the only control panels that I have had to work with are wood and I have a metal control panel that I need to drill some additional button holes and I am wondering if anyone has some tips on the best bits and procure for this.
 
I have a piece of wood that has the hole(s) pre-drilled in it, I clamp that to control panel. Using a new/sharp hole saw, I cut the hole. The wood prevents you from wobbling or losing original spot. Maybe a little oil, but too much and it will seep into art

.02
 
Thanks for the tip. Right now the CP is bare metal so no artwork yet. I was planning in doing a pilot hole and then use a metal 1 1/8 hole bit to complete the hole. So just add a little oil around the hole help the bit run a little cooler?
 
Correct. Wd40 or 3n1 oil. Just go straight down with hole saw. If you tilt or wobble the hole will be too large
 
I've been using the same 1 1/8" hole saw(Home Depot) for some time now and I've drilled many, many holes ALL in metal CP's. Williams CP's are the toughest, since they are both metal and wood. I use a huge ass drill press at work, as long as I line everything up very carefully before I start drilling, I always get a perfect hole exactly where I want.
If you don't have a drill press, you will need that wood with the hole pre-drilled and clamped in place so you don't slip as you're drilling by hand.
 
I like nice clean holes. That's why I use a Greenlee knockout punch.

I know this is an old thread, but I wanted to thank Ken for this tid bit that I wouldn't have known otherwise. I have a Galaga/Ms Pac reunion cab that I abhor the micro switch controller and buttons. I picked up an original Ms Pac panel with the original leaf controller and added leaf fire buttons to it. The knockout punch worked perfectly. It didnt even tear the overlay. I found a used Greenlee punch on eBay for $15. Thanks a lot Ken for the tip. Maybe this will help someone in the future.
 
I like nice clean holes. That's why I use a Greenlee knockout punch.

Ken is correct. The Greenlee 1-1/8" knockout punch is the only way to fly. If you use a hole saw, the chances of keeping your hole where you want it is slim, and it will make razor sharp edges. The knockout punch is expensive, but will last forever and leaves a nice smooth hole with minimal effort.
 
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