fabricating first board

[jlullo]

hey everyone... i am going to start my first pedal project ever by etching a board tonight for the Tonepad Tube Screamer.  I was originally going to just buy a RTS board from Tonepad, but decided that since I was a beginner, i might as well learn from scratch. 

Do you guys have any tips for drilling holes after i'm done etching?  I don't have access to a drill press, so i'm going to be attempting them by hand.

[captntasty]

I have used a small cordless handheld drill on all my boards, so I can say that it is totally doable.  I would add that I would love a drill press as it would eliminate those pesky forearm cramps on complex boards!  The most important thing to have is the proper size drill bit.  I use a # 62 drill bit which is most likely not going to be available at your local hardware store.  Small bear stocks a variety of sizes http://www.smallbearelec.com/Detail.bok?no=376 .  The #62 has worked for me using #24 guage wire which is pretty much standard,  Small bear stocks this in a variety of colors.  If for some reason your using larger guage wire, you might need larger guage bits.  When/if you get them, stock up on multiples...  they will break!  Just the way it is, they're tiny.  I clamp the edge of my board into a small vice with paper or cardboard folded around the board where the vice grabs it, to prevent the copper traces from being damaged.  Then position it at a good angle and drill away.  It's a bit surprising how well the drill bit will stay inside the copper trace, but even if I goof, the hole is close enough to the copper pad to make contact when soldering.
Good luck....
Peace

p.s. forgot to mention drilling holes in your enclosure - not much to say other than get yourself a Unibit, you will thank yourself in the morning... and these are available at the local hardware store! 

[sfr]

I will say, if you make sure to etch until the little holes inside the pad have been etched away, (for some reason, they always seem to be the last part to go, for me) you shouldn't have too much of a problem following the advice above - having the ring of copper from the pad around where you want to drill seems to sort of act like the hole had been centerpunched and keeps the drill bit from wandering.  One of my last boards, I managed to leave the copper in the hole parts of the pad, and the drill bit wanted to wander like crazy.  I ended up needing to punch a dimple into every stupid pad where I wanted to drill a hole.  It wasn't fun or easy.

[jlullo]

thanks guys!  would it be wise to clamp it down on a piece of wood to help secure it?  or is that a little excessive?

[cakeworks]

thanks guys!  would it be wise to clamp it down on a piece of wood to help secure it?  or is that a little excessive?

not  at all... excessive that is.

I drill my holes with a 0.5mm bit in a regular high speed drill and BOY does it suck!

[David]

Dimple the pads first before you drill.  I just use a punch and a rubber mallet.  One tap, and voila!  The PCB material I use is very thin and I can practically do my "drilling" WITH the punch, so now I just tap.  For drilling, I have a Dremel with the tiny collet and a .032 bit.  I lay a piece of wood under the PCB when I drill.  With this and the pre-dimpled pads, drilling is easy.  Unfortunately, it IS time-consuming, and nothing can be done about that.

[Connoisseur of Distortion]

i will add that if you use a hand drill, you are FORBIDDEN from pushing the drill into the PCB. Instead, set the base of the drill on your bench and push the PCB onto the drill bit. MUCH safer and MUCH more accurate.

[jlullo]

thanks guys.. i just ordered a dremel tool specifically so i can cut the board and drill the holes.  I'll take all of your words of advice!