Basic case-drilling tips?

[Rex Dart]

I was just wondering what methods and tools you guys might use for drilling holes in the plastic shells of old game systems when modding them. I try marking a line on the plastic with a straight edge & drawing cross lines where I plan on drilling, but I'm never fully satisfied with the way the jacks line up once installed. My tools are generally a smallish hand-held power drill, some standard drill bits, spade bits, forstner bits.

 

I was looking at an A/V mod walkthrough recently & saw some mention of some sort of multi-diameter drill bit. It was conical, stepped, & had different diameters marked all the way to the base. I can't remember the name, but it sounded useful. Anybody use one of those?

 

Anyways, any tips you can provide would be greatly appreciated.

[horseboy]

I use a really small regular drill bit for a pilot hole and then move on to the forstner bit.

[bigbee99]

I was looking at an A/V mod walkthrough recently & saw some mention of some sort of multi-diameter drill bit. It was conical, stepped, & had different diameters marked all the way to the base. I can't remember the name, but it sounded useful. Anybody use one of those?

 

I've used these when knocking out metal boxes. They work well.

 

As far as lining them up, I'd try the pilot hole method after you lay the holes out. It works for me.

 

B

[RevEng]

Masking tape helps the bit from slipping around and gives you something to make your marks on. The cheaper the better, as the cheap stuff has less adhesive to clean up afterward.

[Rex Dart]

Thanks so far; I'll have to try that masking tape trick. Maybe painter's tape? That stuff's about as un-adhesive as it gets.

[Rex Dart]

How about part sources / part numbers? Anybody care to list where they prefer to buy transistors, RCA jacks, and the like? I've not been happy with the S-Video jacks I find; they have the wide metal "wings" on either side & I'd rather just have them snap in or bolt in like the RCA jacks.

[Chuck D. Head]

 

 

I was looking at an A/V mod walkthrough recently & saw some mention of some sort of multi-diameter drill bit. It was conical, stepped, & had different diameters marked all the way to the base. I can't remember the name, but it sounded useful. Anybody use one of those?

 

Anyways, any tips you can provide would be greatly appreciated.

 

They are called step bits and good ones are $25-35. They make cheap ones ($5-10)which would be fine for plastic, but a few holes in metal and you will feel them getting dull. Another good thing to have is a few countersink bits. If you have a hole where the edges are exposed (a hole for a power LED to poke through the case, for example)the countersink bit can be used to give it a nice beveled edge. Just practice on junk plastic to get the feel of (ie: be smarter than me).

 

Here are a few online retailers I use for parts and whatnot:

 

http://www.goldmine-elec.com/

 

 

http://www.parts-express.com/electronic-components.cfm

Edited August 1, 2011 by Chuck D. Head

[Rex Dart]

So what about drilling holes on "seams" where two halves of a case come together? That's usually what you're looking at when you've got a wide open spot to put A/V jacks, but it seems risky.

[Chuck D. Head]

So what about drilling holes on "seams" where two halves of a case come together? That's usually what you're looking at when you've got a wide open spot to put A/V jacks, but it seems risky.

 

Tough, but sometimes you gotta. Ideally, what I try to do is secure some kind of sacrificial stock material aver the intended site, lining up a pilot hole through both the stock and where the actual goes. Then use a forstner bit or, if size dictates, some other kind of bit to go through the extra material before you hit the case of your console/ computer. This keeps the edges from mushrooming out, developing ridges, etc - just makes for a cleaner penetration in addition to letting the material guide you through. There might be situations where you would want to drill a full size guide hole through the stock and then affix it in just the right position to drill your case.

[Rex Dart]

Well, what I've learned so far...

 

Digi-Key's pretty good for parts. Got a bunch of connectors for about $1 per part. Cheap shipping.

 

And something I feel pretty stupid for not coming up with, using the Channel 3/4 switch on a system to switch that RF jack's function from RF to Composite output. Now I've got a sack of worthless yellow jacks. Oh well.