Switch/Machineing Hole Help

[Eiyame]

How can I make one of these http://www.thecustomsabershop.com/16mm-Anti-Vandal-Momentary-Nickel-Plated-Switch-P471.aspx with a AVbezel. Work on this hilt? It did have a guarded switch on it and I hated the thing from day one, now I'm putting sound in it and want an AV switch if I can do it with out to much trouble.

http://i49.photobucket.com/albums/f252/lexiongal580/Star%20Wars/IMG_0120_zps40566e19.jpg

[Silver Serpent]

The switch you have listed is too short to work with the AV Bezel.

From http://forums.thecustomsabershop.com/showthread.php?11154-Commonly-used-Drill-bits-taps-and-measurements

For the Lighted 16mm anti-Vandal Switch
-To tap and thread; 15mm bit w/ M16-1 tap
-Use a 23/32 endmill to countersink the AV switch. Drill a 5/8" hole first.

That being said, the tap needed is fairly uncommon. You could just drill out the hole or enlarge it with a dremel, but you'll definitely need the nut on the inside of the hilt to hold the switch in place. Another option would be to get an activation box to hold your switch. They're a bit easier to install, and more forgiving if your switch holes get ugly during the enlarging process.

It's definitely doable. You've got a few different ways to get it done.

[Eiyame]

I am not a fan of the activation box's. And the plain switch I want I can't find on the website in a long style. And I don't want an illuminated switch. And what do they mean by tap? I'm kinda new to this. Is there a glossary to be had?

[Forgetful Jedi Knight]

I am not a fan of the activation box's. And the plain switch I want I can't find on the website in a long style. And I don't want an illuminated switch. And what do they mean by tap? I'm kinda new to this. Is there a glossary to be had?

A "tap" is like a drill bit that threads the inside of a hole (think the threading on the inside of a nut - as in nut and bolt) ;)

Your best bet is to make the hole big enough and use a nut on the inside to secure it. I don't think there will be enough material for you to tap threads into.

[Eiyame]

Well I have a drill press so drilling the hole isn't a problem. The problem for me now if getting a silver non-illuminated AV switch with bezel for the silly thing. Anyone got any ideas?

[Jordandau]

You could always get the bezel and sand/grind it down to fit.

[Eiyame]

God point, that. Might just do that.