Need Advice for Drilling Holes for Sink Tube Lightsaber

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SirJediKnightTim

Well-Known Member
I am going to starting on a sink tube lightsaber this week, and need some advise on how to drill thru it. I only have a hand drill.
 

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Kevin Gossett

Master Member
RPF PREMIUM MEMBER
I would advise in at least having a table-top clamp to hold the tube in place. Drill slowly to start out until you get enough of a hole going to guide your drill the rest of the way
 

SirJediKnightTim

Well-Known Member
I would advise in at least having a table-top clamp to hold the tube in place. Drill slowly to start out until you get enough of a hole going to guide your drill the rest of the way
Very good advice, I live in an apartment now and don't even have a workbench anymore. I may have to nail together a small one.
 

SirJediKnightTim

Well-Known Member
i would just use ca glue, or only drill in minimal spots.
Yeah, I am not planning on too much drilling. I am basically making a version that has all of my favorite parts of different lightsaber. For example, I'm adding the copper button that is on the Anakin lightsaber for the top button instead of the bottom. I will probably have to drill to add that.
 

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pfillery

Active Member
If you are drilling into round tube, whether you are using a hand drill or electric/drill press, make sure you centrepunch your hole first, there is nothing worse than starting and the drill slips and puts a dirty great big scratch down your tube. You can buy "no hammer" type punches which you apply hand pressure to, they tension up and then click and leave a mark for the drill bit to bite into.

Also helps to start with a small hole first and use that as a pilot hole to drill the larger hole.

Hope this helps.

Paul.
 

Dakhahn

Member
Sink tube can be fragile when you put pressure on it. I suggest a wooden dowel or something inside the tube to help keep it from collapsing or deforming.
 

SirJediKnightTim

Well-Known Member
If you are drilling into round tube, whether you are using a hand drill or electric/drill press, make sure you centrepunch your hole first, there is nothing worse than starting and the drill slips and puts a dirty great big scratch down your tube. You can buy "no hammer" type punches which you apply hand pressure to, they tension up and then click and leave a mark for the drill bit to bite into.

Also helps to start with a small hole first and use that as a pilot hole to drill the larger hole.

Hope this helps.

Paul.
Very nice, I have never heard of one of those. I will have to get one from Home Depot.
 

Etewaf

Active Member
I'd recommend wrapping masking tape around it too, both for when you use the punch to dent the metal as well as when you drill. It'll protect it a bit if you slip, it's what I do.
 

thd9791

Master Member
RPF PREMIUM MEMBER
I agree with the two above, if it's a sink tube, always ALWAYS somehow make a starter hole, whether it's with a nail or whatever. My first saber ended up having a dowel in the bottom to attach a sink knob so that was a little sturdier, drilling through the two. Though, the top of the saber had many little holes with nothing but the sink tube. Go slow, in spurts and each time make sure the tube is still in shape.

If you're drilling something flat, like the bottom of a graflex tube, Drilling dents the brass inward. Put a thick screwdriver handle down in the tube, while standing it up and rubber mallet smash the screwdriver into the bottom, sandwiching it with the table top. Comes back flat as ever.

If you need to make a larger hole with just a hand drill you can pick the size drill bit one smaller than what you need and slowly go in circles to widen the hole. Like the drilling above, check each pass. Taking the time will save you a lot of frustration.

A simple tabletop clamp is the best. I usually wrap whatever I'm working on in a dishtowel to protect it. Masking tape or electrical tape will work as well!

Hope I helped!
 

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