2017-01-14 (Sa) Tough Pi-ano

Pilot holes were drilled through each of the marked holes. These pilot holes started in the top of the board where the buttons will be visible so even if the holes were not drilled straight they should start in the correct location and the buttons would be positioned correctly. With such large holes and plenty of wiggle room there was no need for this level of precision but it was worth doing correctly.

Pilot holes drilled in wooden board

Every single one of the holes would be drilled from each face of the board to prevent blowout. This can also be done by drilling into a receiving piece of wood but that tends to chew up scrap wood pretty quickly with such large holes.

Holes drilled halfway through board

The same Forstner drill bit was used to drill through the plastic. Drilling plastic, probably PVC, with a Forstner bit meant it had to be cleared often. As the bit heated up it needed to be cleaned after every hole. Dipping the bit up and down while drilling also helped to keep the sides of the bit clear and lead to cleaner edges of the hole.

 Holes drilled through plastic sheet and wood

Only one hole was missed my accident. A half-note was missed but it should be no problem to make it up on the drill press next time. Accurate measurements produced wood and plastic which lined up well. The selected buttons were long enough to pass all the way through the board and plastic and still have enough exposed threads to catch the nut on the inside.

 Wood and plastic drilled

Considerable dust and debris was produced. Always keep your work space tidy! Especially when working in a community space.

Mess under the drill press


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2016-12-22 (Th)