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Home Brew Analog Computer System
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GK:
Hmmm. I've got a "unibit" (10mm to 22mm step sizes) but didn't consider a smaller one as the damn thing became hopelessly clogged up drilling aluminium in the past. Just re-jogging my memory getting back into this now, the banana jack datasheet specifies an oddball 8.33mm hole (rather than 7mm) so I guess 1/3” will do.

http://www.newark.com/pdfs/datasheets/spc/TA-376.PDF
robrenz:
That 8.33 is probably clearance for a 5/16 or 8mm.  Get some TapMagic aluminum cutting fluid and that will keep the unibit from clogging up with aluminum an give a nice finish.
GK:
Okkaayyyyyy........ I'll pick up a smaller diameter Unibit, a 5/16 centre drill and some appropiate cutting fluid tomorrow. See how I'll go with that.
poorchava:
I'd say find a job shop or become friends with someone who has an access to a CNC.
woodchips:
If you want several panels then much the best way is to make a jig from some 3mm or 1/8" steel 19" panel. This will drill much better than aluminium. Then drill through the steel into the aluminium panels, can do 6 at once. If drills don't work then try a 3 flute slot drill with centre cutting. Alternatively punch the holes again using the jig.
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