cutting holes

[Rick Jansen]

I make fronts with 2mm (a bit less than 1/10th of an inch) aluminium
sheet metal, which I have my supplier cut the right size. The fronts
of the Formant come only in two sizes. 99% of the holes are round,
for pots and switches and connectors. I use a punch to make a dent
for the drill. With a series of drills increasing in size I enlarge 
hole, if a really big hole is necessary I use a taped reamer. If 
you're only working on one machine for your hobby I guess it's not
worth while to get expensive machinery... Coarse files work very very
well and quick in aluminium. 

The only thing is that I use standard drills intended for steel. It
often happens the drill fills itself with aluminium, and sometimes
the drill wanders a little bit off-center. Does anyone here have those
drills especially meant for aluminium? The angle of the cutting edges
are different for those drills. Experiences?

Rick Jansen
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rick at sara.nl   http://www.sara.nl/Rick.Jansen
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S&H's a module and s&h's looking good