figured i’d do a crosspost here with some of the things I’ve learned after hand-drilling and cutting a plywood panel:
This is cheap 3mm birch ply. I still haven’t pulled the trigger on the table saw so I cut the panel with my jig saw…turned out a lot straighter than I’d done in the past…some quick sanding and I was good to go. I used masking tape on both sides, and an “xtra clean” bosch blade and it worked great with no splintering.
For drilling (just using my hand drill), I did the masking tape on both sides again. I did some experimenting with my leftover pieces and found out that stripping at the back was gonna be a huge problem, so I tried the “backing board” trick and it definitelly helped. There is still a fair amount of stripping but the tape and backing board definitely makes i non-terrible. The irwin unitbit set I have did seem to do better than the craftsman bit set I have in terms of stripping.
My dad gave me a bunch of quick vices and they made things go very smoothly…much better than the rotary vices i was using.
My approximate cuts weren’t exact to the parts, so I did some small tweaks with the dremel to get things to start to seat. Then, I took a pen and marked which holes and where needed to be enlarged to get things to seat fully. I took the unibit and I increased the hole sizes with some fairly light pressure in the direction they needed to open up. I couldn’t use a backing board for this, and so I was nervous, but luckilly no super bad stripping happened. This worked great, and the unibit was so much faster than the dremel.
One other trick with the unibit I figured out was if you do some masking ttape to the level you want to go, it makes it a lot easier than eyeballing or trying to feel for the clicks.
I’m pretty happy with how it turned out! Far from perfect, but I don’t think it’s too terrible. Hopefully this helps if anyone wans to experiment with drilling plywood panels for synth things.