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4. In this step we will drill a 1/4" (6 mm) hole in the chassis. For this process you need to be very
careful. This is by far the most dangerous part of this whole operation. Use work gloves and
safety goggles. If you have a drill press, use it. If you are not qualified to drill a hole in the
chassis, do not attempt it. Get a qualified friend to help you.
In this process, we will not try to drill out the 1/4" hole all at once. We will first drill a small hole
through the chassis and then use larger bits to increase the hole size.
a. Place the block of wood behind the face of the chassis that will be drilled, as in the picture.
Mount the chassis and piece of wood in a vice to hold it steady, with the surface to be drilled
facing up (11).
b. Start by drilling a 1/8" (3 mm) hole. Put the bit in the chuck as far deep as it will go. Align
the bit to the divot you made and start drilling on low speed (12). Go slow and use constant
force against the metal. Do not let the drill bit slip away from the divot. If it slips away, re-align
and start again.
c. Now re-drill with a 3/16" (4, 4.5 or 5 mm) bit. Drill very slowly.
d. Finally, drill out the 1/4" (6 mm) hole in the same way (13).
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