How do you guys form your enclosure?

[ChuckZilla]

Hello All,

Newbie in the forum and to the foot pedal making game. I have some aluminum enclosures from taydaelectronics. hey are high quality, and about 2 mm thick. I was wondering how do you shape your enclosure?

I would guess you use a drill for the holes, but what tools do you use to shape other things, like a square for a DC barrel plug input?

I'm sure this topic has been covered before, but I couldn't find it. Feel free to direct me to another link.

Thanks,
-Chuck

[LucifersTrip]

just a drill....everything's a hole. for the DC jack, especially if you're ordering from Tayda, you'd use these

http://www.taydaelectronics.com/dc-power-jack-2-1mm-enclosed-frame-with-switch-external.html

the biggest problem for me at the beginning was getting a drill that could handle a .475" bit. my old drill could only handle up to .39"

[ChuckZilla]

Thanks for the advise! I have been buying the wrong kind of DC inputs.

[aion]

Your best bet if you need a square hole is to drill a circular hole with the diameter of your square and then use a file or some sort of Dremel attachment to hollow out the rest. But, you'll notice you won't see a whole lot of DIY pedals with those type of DC jacks, and after one build you'll know why :)

I'd also recommend getting a set of step-bits. It'll make the drilling process a lot easier:

http://www.amazon.com/Neiko-3-Piece-Titanium-Drill-Steel/dp/B001OEPYWK

These ones are great and a good price as well. Most hardware stores will sell the Irwin Unibits, but those are usually twice the price and not much better for what you need them to do.

[reverberation66]

    I agree about the step bits.  It'll save you a bunch of time and you'll get more consistently good results.  I just started using these recently and they make a world of difference, I was thinking of buying a drilll press but the step bits yield good enough results that I feel like that can wait for a while.  Plus it's way faster:)

[R.G.]

I've always been a fan of explosive forming techniques, but the licensing requirements are tougher than they used to be.

[Earthscum]

^^ 
I was thinking along the lines of Chuck Norris fear induced forming.

[Perrow]

My enclosures sit on the shelf waiting for erosion to make holes in them, but when I get impatient I use drills and a reamer.

[Strat68okc]

Harbor Freight has a cool set of step bits for about $12. I've been using those when the erosion method takes too long.

[deadastronaut]

My enclosures sit on the shelf waiting for erosion to make holes in them, but when I get impatient I use drills and a reamer.

lol..yep, i'm  a drill and reamer guy too..

[Mike Burgundy]

+1 on the step drills.
Aion - that's a good price on Amazon! Are they any good? I've had step bits g dull on me after just a couple of Al enclosures, but I also have two that survive even stainless sheet without any problems for years now.

[digi2t]

the biggest problem for me at the beginning was getting a drill that could handle a .475" bit. my old drill could only handle up to .39"

For those with small drill chucks (3/8 max. capacity), many drill bit suppliers/retailers sell sets that have the larger size bits over 3/8 with the shanks machined down to 3/8.

I had a small press drill with a 3/8 chuck for many years, and having one of these set saved me a lot of aggravation. Especially since you can use a 1/2 bit in a small hand drill.

[scuzzphut]

On the subject of DC jacks - I just ordered some of these ....
https://www.taydaelectronics.com/catalogsearch/result/?q=DC+Power+Jack+2.1mm+Enclosed+Frame+With+Switch+External

They would appear to solve the problem of having to desolder the DC jack every time you remove it (mock-up, repainting, etc).

Didn't know they existed - thought some of you fellows might not know either.

[petey twofinger]

i oil my step bit every time i use it , not sure how much it helps , but i am cheap .

[Jdansti]

i oil my step bit every time i use it , not sure how much it helps , but i am cheap .

+1
If I'm drilling through a thick piece of metal, I put a little motor oil on the tip of the bit before I start and about every 5 seconds of drill time afterward. It really helps the bit cut and probably helps avoid getting it too hot. I clean up the work piece with lots of alcohol.