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Drilling

I drilled out the holes to 7/16" per the template and then setup to chamfer each hole so that the angle of the tapered 1/4 20 hex bolt head would sit just in the hole with out falling all the way into the body and sit just about flush with the outside of the tube. This part can be very tricky if you have never done it before so be very cautious and take your time. You can also use a countersink bit, but make sure you have a wooden dowel inside the tube when drilling.

 

This is the style of industrial chamfer bit that I used.

Introduction

Parts

Template

Drilling

Ear Bending

Test Fit

Painting

Bottom Shell

Install Parts

EL Elect.

The Joining

Finishing Up

Finished Pics

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