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Bill's RV-10 Builder Page
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Date:  11-13-2008
Number of Hours:  6.00
Manual Reference:  
Brief Description:  switch holes

This all works surprisingly well and easily.
1) mark out the holes
2) drill out as much of the hole as you can (but don't get carried away)
3) Use a corse square file to finish the hole out (remember, 1 direction (push) only)

the filing only takes about 3 mins per hole.

Layout tip - to keep things looking professional and "machine made" , layout a an evenly spaced grid for the holes, then only drillout and file the holes you want. If later you need to add a hole, everything remains space correctly. In any case, it look CNC-like even though you used a lousy file.
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drilled out holes with file ready to go

drilled out holes with file ready to go

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Switches inserted.  They friction fit within your filing tolerances - no problem

Switches inserted. They friction fit within your filing tolerances - no problem

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