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Date:  4-17-2011
Number of Hours:  1.00
Manual Reference:  Sec 27 - Firewall
Brief Description:  Control Cable pass-throughs

I screwed up my first recess when I realized too late that the stardard pass-through locations in the recess were too close together to use the eyeballs after starting to open the holes up. So I had to order a 2nd recess form Van's that arrived in short order. The SS eyeball pass throughs I have require a 1 1/8" hole for the socket to rest in. Problem is my largest step drill bilt only goes up to 1". Plus, in my earlier attempt to enlarge the cable holes with a unibit was less than satisfactory as the bit created significant tearout around the hole due to the SS (you can kinda see it in pics 1 & 3). The best tool for the job is more than likely a punch, but I don't have any and didn't want to go buy one (even if I could in my local area which I doubt). So I decided to do it the hard way. I drew an appropripate sized circle on the recess after choosing locations centered on Van's existing holes. I then used a #40 bit and drilled along the inside circumference. Then I cut the circle out with my Dremel and filed the hole smooth.
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Drilling out the pass-thorughs

Drilling out the pass-thorughs

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Closeup of my solution

Closeup of my solution

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Another view

Another view

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