Drill a switch hole

[Ki-Djowac]

Hello everyone,
here's my problem : i want to drill a bigger switch in my TCSS hilt part and want to have an edge around the hole so the switch falls nicely in the hilt.

Anyone knows how to get this done please ?

[Rhyen Skytracker]

I use a step drill bit to drill bigger holes. I use one like this one http://www.google.com/products/catalog?hl=en&q=step+drill+bit&ved=0CDMQrQQwAA&cid=12354006758512672305&sa=title#p You can drill any size hole you need up to 1".

[Jedi-Loreen]

He's wants a bevel too, though.

[Sunrider]

You must complete your training in the dremel arts.:)

[Rhyen Skytracker]

That is the great thing about step bits. You drill a little deeper and it make a slightly larger hole on the top and the correct size on the inside. You have to be careful not to go all the way through with the larger size though.

[Jedi-Loreen]

Yeah, I know that, but can you get a wide enough bevel that way?

[Rhyen Skytracker]

Of course not, what a silly question. LOL Just kidding. It depends on how much wider you need it. The best way to get a wider hole is to use a mill and an end mill bit.

[astromech_kuhns]

if you do decide to go the step bit route, make sure you go to HF and pick up the 3 pack of $9.99 or something of the sort, its right around 10 dollars. and it comes with three. will do you good for what you plan to use them for.

[Dakarn]

HF being Harbor Freight?

[Lord Maul]

Correct ;)

[Ki-Djowac]

Hey guys,
thanks for all the input.
Here's what i'm thinking :

The step drill bit is a good idea but the edge i need so the switch falls in the hilt needs to have a straight edge => L . The step drill gets me a "conical" edge (unless i have another kind of step drill).

The end mill seems to do the trick, but i'm thinking of a good way to keep the drill centered.