Drilling a square hole

Easiest thing to do is to drill a regular round hole, then file it out until it is square with a square jewelers file.

...or just drill a hole large enough for the slide switch to function properly...or just use a toggle switch.

Matt

Thats what I did.  It's underneath so nobody's going to see it anyway.

This comes up with the PS-2 upgrades also it you need to install the rectangular charging port.  The manual doesn't address it, but the old PS-1 Aux tender kits did.

If you want a cleaner look, and less filing, use a smaller bit and drill holes at the corners of your template.  You can go 4 small holes or with a slightly larger bit 2 holes.

Normally, I drill the first one part way, then drill the second hole all the way thru.  If the holes will overlap the drill bit can walk into the first hole, if it is all the way thru.

The small various shaped files you can get a the tool stores work great at opening up the whole and then squaring it of.

Takes a little more time, but if it is an expensive engine and you want a factory look, the above method works.  G

Or you could use one of these.

http://www.youtube.com/watch?v=ALiqAXiTQBg

Pete

I always just file it out with a small file.

Pete, somehow I don't think he has a milling machine handy for this task.

Thanks for all the tips.  I really enjoyed the video and I love tools, but may pass on that one!

I program the engine with the body off. I do not drill a hole, I just leave the switch inside the engine. After the engine is programed I install the body.

I like to be able to reprogram the engine after I put it together, it's a PITA to take the shell off anytime I want to program a new ID or reset it.  Since the switch is under the engine, it is not a cosmetic issue to have it exposed.

I always just drill a round hole large enough for the task, using a step bit.

Rod