On Sun, 10 Apr 2016 05:41:08 -0700 (PDT), "
wrote:

On Saturday, April 9, 2016 at 8:17:32 PM UTC-4, John Doe wrote:
whit3rd wrote:

If you have a well-lit bench

I have the best possible lighting, always and everywhere

http://ecx.images-amazon.com/images/...L._SL1080_.jpg

I assume " no tools " really means no expensive tools. But even there I run into trouble. If I were doing it I would use a drill press to remove most of the material. And then would use some small files along with a machinists square to " file to fit ".

Dan

Do you have a machinist's square that will get inside of a 1/2" hole?
g

I think he's stuck with Tom's suggestion of using a jeweler's saw and
finishing with a regular fine-tooth triangular file, unless he has
chisels and coarse-tooth files made for aluminum.

--
Ed Huntress