"Alan Kamrowski II" wrote in message
...

Hole needed 1 1/8", overhang 1 5/16". See picture at:
http://home.earthlink.net/~alank2/image001.jpg

But those are diameters. So you have to divide by two to get the actual
"overhang". In this case, 3/32", way too tight a tolerance for using hole
saws. Also realize that if the holes are loose, your buttons may wiggle
around when the arcade action gets hot.


Hole needed 2 1/4, in this case underhang 2 9/16". See picture at:
http://home.earthlink.net/~alank2/image002.jpg

In this case, the cut hole will be visible on the top of the panel (unless
you have a piece of trim to glue on top). All the more reason to make a
precisely sized and shaped hole.


I was thinking about using a 6pc kit with built in arbors such as
http://www.lenoxsaw.com/aholswkt.htm , but you've convinced me to do
otherwise!

These arbors are not "built in"; they simply include a screw on arbor for
each saw in the kit (so there is still the problem with wobble, etc.). Btw,
you said you wanted to save money: each of those kits probably runs over
$100, perhaps over $200.

But enough words have been wasted on hole saws.


I have found that my drill press only goes down to 585 rpm at the lowest
speed.

That's too fast. You're going to want something around 100 rpm.


Do you think I can find one at Lowes or HD ?

Probably. Go take a look.


Since you said you have more than 10 holes to cut, you may have to
sharpen
the HSS bit once or more during the job.

I got you.

That's assuming the panel is sheet steel. If aluminum, you may be able to
get away with doing the whole job without sharpening.


The best would be water-soluble oil, as that has the greatest cooling
properties (to protect your powdercoat finish).

Is this something available a Lowes or HD as well? Would it be in the
cutting/drilling section?

Nope, not available at any hardware store. If you're cutting aluminum, you
can use straight kerosene (it shouldn't affect the finish, but test on a
small spot first). If you're cutting steel, then you're going to have to
hunt around for an appropriate cutting fluid.


Once again, thanks for all your help, I really do appreciate it!!!!

You're welcome. Good Luck.