How do you guys drill your enclosures? Drill templates not lining up...

[pickdropper]

Lots of good advice here.

I lay out a drill template in Illustrator (Inkscape would work fine as well).

I recommend buying an inexpensive set of calipers; they are invaluable for double checking the spacing on the actual PCBs with board mount pots.

[3petedt]

I use PowerPoint for graphics and hole placement.  Draft copies get taped to a piece of cardboard and I then I cut out the holes with an xacto knife and mount everything.  I do a lot of measuring twice to drill once.  Doing the layout on cardboard helps with 3D so you can see where problems might occur with interference and such. 

[Scruffie]

Set Square, Eye, Guess work, Sharpie Marker, Circular File for mistakes   

Not had an un-useable enclosure from it and have made some tight fits! This is with board mounted pots, but I do measure and check a lot... not the best way really.

Started experimenting with the Express PCB files i've made now to measure by mm with a cross grid and print it with datasheet part outlines, not tried it yet though as I gave my printer away but seems sound.

I think even if you don't use express PCB it could be a viable option just for templates.

[Rockhorst]

I use vinyl sticker for my graphics, they're very scratch resistant. I sometimes include the drill template in the artwork. Put on the sticker and drill on.

I've started drilling the holes a bit over sized so I have some room for adjustment. I convert the image to PDF, this helps a lot with the printing usually. Then I test fit everything together in Photoshop.

[drezdn]

There's always the T-Handle Reamer if your hole is slightly off.

[DutchMF]

There's always the T-Handle Reamer if your hole is slightly off.

Sorry, but this just sounds so............ wrong? I'm so glad no holes were 'slightly off' on my last build! 

Paul

[Emmy]

The best part of this thread is hearing that others share my difficulties with drilling.   My excuse is that I don't own a drill press, or padded vice, or the space in which to place those tools. 

Keep on filin'

[mjcyates]

I don't ever use a template. I cover the enclosure in painters tape and then use a ruler a T-Square and a pencil to mark it up.

[stevie1556]

I've recently stopped using a 7mm drill bit fot the pots and instead using the 8mm part of my step drill. Gives me a chance to move the pots around slightly and they always line up perfecrly now. That was always the worse part of a build for me, and if the pots weren't perfect the box went on the scrap heap and I tried again!

Sent from my thumbs using Tapatalk!

[TwistdDeth]

Dremel. Dremel fixes everything!

Here is something I found this weekend at a yardsale for $10


Also got a mortising kit by craftsman and a set of bits with the Drill press!