Need help on boring out a Solitaire

[crampedson]

How should I go about boring out a Maglite Solitaire body like so:

I don't have a drill bit close to that size!

 

[will]

There is a groove for an 'O' ring that measures .405 inch. The inside diameter near the head is .295 inch. (estimate) That leaves a wall thickness at the groove of .055 inch. The inside diameter of the lower area, where the battery goes, is .417 inch. If you bore it out the diameter of the lower part, you will break it at the groove. Probably the most you can remove is .025 off the wall thickness, that is an inside diameter of .345 inch. That leaves the a wall thickness of .030 at the groove. You might be able to cut smaller, but not by too much.

You should be able to pick up a fractional drill size in most stores that sell tools. each 1/64 inch equals .0156 inch, drills are sold in fractional sizes by 1/64 inch.

hope that helps.

 

[crampedson]

Yes it IS a help, I didn't know too much about the measurements inside the cylinder. Guess this means a trip for drill bits then.

 

[will]

One good thing about the solitaire, they are less than $5.00. I use the corner of a single edge razor blade to pop off the switch. The switch is 2 parts, pressed together. Be careful not to lose the tiny metal parts in the switch.

 

[gadget_lover]

If you use a drill for this, be aware that if you go off center you will go through the wall. You also need to find a way to hold it securely. The temptation to hold it in your hand should be resisted.

Daniel

 

[will]

If you use a drill for this, be aware that if you go off center you will go through the wall. You also need to find a way to hold it securely. The temptation to hold it in your hand should be resisted.

Daniel

so very true.....

 

[LukeA]

I hate to be a wet blanket, but I don't think this will work. I think the hole wil end up off center if it doesn't break through the side of the body. Drill bits, especially fairly small ones like the one needed here, are prone to flexing to find the path of least resistance through the material. And with a wall thickness that small, holding the body in a vise tight enough to keep it from spinning will cause it to flex, which will leave the finished hole out of round. Those are my concerns about this job when using a drill press. I wouldn't attempt it with a handheld drill.

Ideally, this should be done on a lathe, but as mentioned before, soli's are only ~$5.

Keep safe.

 

[scott.cr]

I hate to be a wet blanket, but I don't think this will work.

I agree with this assessment. Plus, when the drill turns into stationary work, the hole tends to be triangular. (When the work is turned and the drill is stationary, the hole is much rounder.)

A chucking reamer might be a better cutter for this job, but it will require more muscle to turn, you'll need to withdraw it frequently to clear the chips, and will cost more than a drill bit.

 

[will]

Reamers are generally used to remove a very little amount of stock. This is to provide a good finish on the inside of the hole. One item, not mentioned, is the end of the hole will not have a flat bottom, it will have the same angle as the drill or the reamer.

You will sometimes get a triangular hole when you drill the first hole in solid stock. If the item is held firmly in a vise, the drill will follow the hole and come out round. I do this all the time. This is done so the finish drill size will be close to what is should be. Sometimes drilling the hole with the finish size only will result in a slightly larger hole.

At any rate - the best way to enlarge the solitaire is in a lathe.