Drilling Question

[Zigzago]

Since I'm not the handiest craftsman around, I thought I'd ask you guys before plunging ahead. Alot of mods require that you drill out an existing reflector and/or lens to accommodate an LED. I'm specifically thinking of a 5mm LED in a Solitaire.

How do you secure fragile pieces like a reflector or lens while drilling to prevent them from breaking or simply spinning with the drill? Do you just use a vise or is there a better way? Thanks for any info.

 

[PaulW]

Zigzago,

I have never drilled a reflector, but I have used a Dremel. I wanted to secure the reflector and get my fingers away from the cutter. So I made a jig. It acts like a vise but is more gentle.

Onto a 3/4 inch board I screwed two short 1x4s that I had cut into trapezoidal shapes (30 degrees off of perpendicular). Since your reflector is smaller than mine, you may need to use narrower pieces of wood. I placed the two pieces in such a way that an angle of 60 degrees was formed. I snugged the reflector, face down, against those edges. Then I placed a 3/4 by 3/4 piece on the large board and slid it up against the edge of the reflector. Each board was now touching the reflector 120 degrees apart around the its edge, and the reflector edge kept the 3/4 by 3/4 from contacting both other pieces; there was a small gap. I then bridged the gap by screwing the 3/4 by 3/4 to the two trapezoidal pieces, tightening until the reflector was secure.

It's easier to build than to describe. Wish I had a camera. Good luck.

Paul

 

[Zigzago]

PaulW,
Thanks, I can visualize your description. It sounds like a good way to go.

 

[PaulW]

One more thing -- a powerful drill can really grab the aluminum of a reflector. I would recommend securing the jig tightly in a vice and feeding the drill very slowly.

Paul

 

[Slick]

I like to hold small parts with "sparkplug boot pliers" that I can drill (without a drill press). That way if a bit breaks, it won't go through my thumb..

 

[MR Bulk]

If the required hole size is not too much bigger than the original, I use successively larger drill bits screwed through BY HAND, starting with one the same size as the original hole to initially clear off any burrs or rough edges, etc. -- absolute guarantee of no damage.

 

[Y2Kirk1028]

[ QUOTE ]
PaulW said:
One more thing -- a powerful drill can really grab the aluminum of a reflector. I would recommend securing the jig tightly in a vice and feeding the drill very slowly.

Paul

[/ QUOTE ]

Yeah, I'd learned that the hard way when I tried to drill a Tigerlight reflector in a vise using a drill press. Completly destoryed the reflector like a piece of gum wrapper. /ubbthreads/images/graemlins/icon15.gif Now, I use a round file on plastic reflectors and hand drill on thin metal ones.

 

[Zigzago]

Thanks for the tips, people.

 

[Doug Owen]

I suggest a tapered reamer. I have two, one with a screwdriver handle goes up to a bit over 3/8 inch, the other has a 'T' handle, and goes close to 5/8. Each has 8 or so flutes and cuts plastic and metals (even mild steel) with relative ease and leaves a smooth surface.

Standard 'large hardware store' items, cost $15 or so, but last a lifetime.

Doug Owen