work on the Satellite Enclosures

I added some pics to the Bluto 555 Electrical gallery to show some work done on the Satellite Enclosures, which are 16 gauge stainless steel, so I had some learnin' to do. Each Enclosure needed 6 holes cut: one 1/2", three 30mm, and two smaller (I forget what the small size was now).

The best way to do this on the larger holes is with knockout punches. Be careful, knockout punches can be really expensive for uncommon sizes, such as 30mm, but they make a very clean cut. Here's a link to a youtube video I watched to learn more about knockout punches before I cut my first hole.

A couple of lessons learned about drilling and cutting stainless:

(1) slow and steady with a good amount of force pressing on the stainless is best. If you start thinking you have to speed up the drill a bunch to make progress, you're probably going to end up going too fast, which easily makes the affected spot too hot and actually makes it harder to drill. Remaining at a slow speed and increasing the pressure applied works best. How many rpms is best? I'm not sure, but I kindof got the feel for it within a few holes.

(2) Use machine oil where you're cutting, both for drilling and using the knockout punches.

(3) For drilling (even when using the knockout punches, you have to drill a smaller hole first), use a drill press if you have access to one and it will work for the spot you're drilling. Drill presses can be set to a slow rpm, and it is really easy to apply consistent pressure. My neighbor insisted I use his drill press when he saw me using a hand drill, and using the drill press was almost like cutting butter in comparison, so I'm really glad he did. Gotta get me one of those sometime.

In one of the pics, you'll also see the sockets installed, which is where the process components for each kettle plug into.

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Click here for more pics of the Satellite Enclosure hole cutting process.