Preparing the tin!

[Lphillimore]

Hey Guys,

Just adding some pics of how I prep the tin on my builds.

It may or may not help you but I've seen a few people struggle and a few have asked how I do mine...so here goes...

What I use:

- Hand drill - 0.5mm drilll bit
- Cordless drill - 4.0mm drill bit (dont have a 3.6mm)
- Wermys3D printed hole guide (recommended!!)
- Fine point Sharpie
- Selection of hand files

I'll break this down into 2 sections, Front and Back.

Front of tin

Mark out your power switch and micro usb charge port using Wermys 3D printed guide and a fine point Sharpie.

Drill pilot holes using a 0.5mm drill bit. I use a hand drill for all pilot holes. (2 pilot holes for power switch, 3 for charge port).

Use needle hand file to merge pilot holes into one.

For power switch i use tiny switches so the merged hole needs smoothing with needle file but that's largely it. Remove any shards from inside and ensure smooth.

For charge port, once pilot holes are merged, i use a flat file with one curved side (similar to a micro USB charge port shape) to slowly file into shape. This should produce a neat hole. Apply extra pressure to each side of the hole to widen if necessary. Smooth with a needle file and remove all shards etc.

Test with a micro usb cable for fit as you go.

Back of tin

Tactile switch holes are fairly easy. Mark with a Sharpie using the 3D print guide then, using a hand drill (0.5mm bit) create pilot holes. I then use my cordless drill (4.0mm bit) to slowly widen pilot hole then speed up until it's done. I have had good results like this. You may want to use a middle of the road drill bit in-between as if you get it wrong with the 4.0mm you could wreck the hole.

Smooth up and remove shards as before.

Same procedure applies to a safe shutdown tactile switch.

Hope it helps!

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Not perfect by any stretch but tidy enough

[dryja123]

Thanks for posting a guide! I'll share my secrect on how I cut my holes as well.

Invest in a 7134 diamond grit filing bit and a 125 carving and engraving bit. 

Use the tin cutting guide and use a fine tipped Sharpie and mark where your cuts are going. Mask off ever part of the tin that is not getting cut to prevent scratches if you slip with your dremel and files. 

Set your dremel to 7,500 rpm and use the 125 bit to start several small pilot holes for the power switch and power port. Youll notice that the 125 bit doesnt walk and cuts true with little force. 

Once you have decent pilot holes, use the 7134 bit to start opening them up. Once you've opened your holes up enough to get the files in easy you'll want to finish and shape them with a half round file for the power port and a rectangular flat file for the power switch. 

The L and R buttons are super easy. Use your 125 bit and expand the holes slowly until the tact switches fit. You may find that some metal will flare on the inside of the tin. Use a round file and file away the flared metal from the inside if the tin. 

Remember, go slow and perfection will come from your tin prep. Invest in those dremel bits and the process will become effortless. 

One last tip: Just like coloring, stay in the lines! If you find that the micro usb cable won't fit do not make the hole wider, make the hole rounder on the bottom but flat on top. You'll be tempted to make the hole wider, don't!

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[ICMF]

Tip:

You will get cleaner, neater results using diamond grit files, rather than cut files. The teeth on a cut file will bite and pull on the metal, leaving you with rippled and stretched edges; diamond grit files are basically smooth, so they abrade the metal more cleanly. As an added bonus, they'll reduce the amount of loud, annoying squeaking, too.

[Lphillimore]

Tip:

You will get cleaner, neater results using diamond grit files, rather than cut files. The teeth on a cut file will bite and pull on the metal, leaving you with rippled and stretched edges; diamond grit files are basically smooth, so they abrade the metal more cleanly. As an added bonus, they'll reduce the amount of loud, annoying squeaking, too.

Good shout - I dont doubt it. For me this will suffice just fine but for absolute perfection I agree

[dryja123]

Added my experience and tips to the second post