red pill sanctuary
Senior Member
Today's misguidance is tomorrow's future!
Posts: 95
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To get started drilling up these panels if d.i.y., stack the amount of 1/2 inch panels ( MDF or plywood ) together and secure with pilot holes through each of the four corners. Then drill up to the size of retaining bolts used to keep these panels securely together for the entire time they are being drilled. These must also be secured around the perimeter with clamps to keep the layers from expanding with the pressure of the drill bit as it passes through the stack. Once that happens, debris works its way between the rise in the sheets causing miss-drilled alignment and blow out between the holes. Once that happens, you need to start over again with new material. You certainly don't want to drill each of these panels independently, or you just may take five years doing it. The best solution here is to have a local CNC shop do this for you if possible. The results will be quick and perfect, and you won't have to do this by hand. I think four to five 1/2 inch panels are going to be the limit for what you can drill by hand simultaneously.
Just remember this, the bottom sheet is going to be sacrificial due to excessive blow out caused by the drill bit plunging through without something flat against it. I did not want my table full of holes, so the bottom sheet was placed on riser blocks for an airspace underneath the stack. Simply means that your bottom sheet is not usable and will be discarded. If done on a machine, this would be avoided. When these panels are drilled out, the end result will be fifty percent of the panel area removed due to the material drilled out. These panels are based upon a 50/50 absorption/diffusion rule. The holes of course represent the absorption factor, which by the inherit design of this hybrid model, also works to create the balance of diffusion by doing so. As seen, this stack of panels is well advanced through the drilling stage. Just showing you the stack set up from the side perspective using clamps to keep the panels from rising under pressure. This is extremely critical that you monitor this process. A mistake here would be devastating. I guarantee you this will ruin your day, and then some! I have three words to describe whether or not you will be successful in completing this task without failure: (DISCIPLINE + PATIENCE + ACCURACY)This process of drilling is done in several steps. To try and skip these steps would be foolish and unprofessional. First, the accuracy of the layout must be as perfect as possible. Whatever mistake happens with the top sheet continues through the entire stack. These holes are very close together. In order not to have conjoined holes or a weakened structure due to lack of webbing between the holes, the centering of these initial pilot holes must be the proper distance from each other. Just as importantly, these holes must be maintained perfectly straight from the top to the bottom. There can be no deviation and there is very little room for error.
This of course requires the use of a drilling platform which can be repetitively used with perfect accuracy each and every time you drill a hole. Another good reason for using a CNC machine. The option I took was to create my own drilling platform which is completely mobile, accurate, and easy to place in any position. I built a drilling rig out of spare parts from a torn down microwave and some other odds and ends I had laying around. The end result was a fabrication which no tool on the market can compare with, especially when this rig cost me nothing extra to assemble. Just make sure that a heavy duty high quality drill is used along with very high quality bits such as titanium coated that will last without dulling easily.
Second, after the layout is completed and checked for accuracy, it is time to indent each and every drill location for the drill bit to catch and remain stable without drifting from center.
Third, each and every drill location must be drilled with a pilot hole much smaller than the actual diameter of the finished hole. This allows the final drilling process to execute flawlessly without fear of being off center. The bit will find its way every time without fail. The end result will be far less tear out and drift. Your holes will be much cleaner and visually pleasing. This process takes a great deal of time to complete by hand. If time is an issue, then you better get a shop to do it for you.
Fourth, step up to the final drill bit size and slowly bore the holes being careful not to over stress the MDF which will lead to lifting between the material and imminent failure.
There will be a huge amount of debris from the drilling. It is advisable to have a shop vac with a dust collection system to keep the MDF dust to a minimum. Half of this material will end up as waste. After drilling so many holes, stop and vacuum up the debris from the holes and area in general. You will also need an orbital sander to keep the surface flat and smooth for the drilling rig base to glide over. If you place the bottom of the base over a drilled area that has not been sanded smooth, you guessed it, this will cause the drill bit path to wander off center and destroy your panels. That amount which is off in the first panel goes up exponentially by the time the drill bit passes through the last panel. Ends up being quite a bit of deviation. This is simply not acceptable.
YOU CANNOT ATTEMPT THIS BY DRILLING FREEHAND. THIS SIMPLY WILL NOT WORK!In my case, I had to drill 11,625 holes with the drilling rig. For three sheets of material, or three binary panels, that would be a grand total of 34,875 holes! DO I NEED TO STRESS THE IMPORTANCE OF THIS ANY FURTHER? I think the point is obvious and clear.
BTW, I only had to replace the titanium drill bit once, and that was after 80 percent completion. The replacement bit is still in use and very sharp. It pays to use high quality tools.
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