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<DIV><FONT face=Arial size=2>Many thanks for the detailed insturctions
Ron.</FONT></DIV>
<DIV><FONT face=Arial size=2>I think that I will use my drill
press.</FONT></DIV>
<DIV><FONT face=Arial size=2>Gene</FONT></DIV>
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<DIV style="FONT: 10pt arial">----- Original Message ----- </DIV>
<DIV
style="BACKGROUND: #e4e4e4; FONT: 10pt arial; font-color: black"><B>From:</B>
<A title=sec@overspianos.com.au href="mailto:sec@overspianos.com.au">Ron
Overs</A> </DIV>
<DIV style="FONT: 10pt arial"><B>To:</B> <A title=pianotech@ptg.org
href="mailto:pianotech@ptg.org">Pianotech List</A> </DIV>
<DIV style="FONT: 10pt arial"><B>Sent:</B> Monday, November 13, 2006 1:43
PM</DIV>
<DIV style="FONT: 10pt arial"><B>Subject:</B> Re: Drilling into
Polyester</DIV>
<DIV><BR></DIV>
<DIV>Gene,</DIV>
<DIV><BR></DIV>
<DIV>Drilling into polyester is quite straightforward using twist drills. The
trick is to have the drill bit very sharp with a lower clearance angle than
normal, so that it won't bite into the material too quickly. I generally
sharpen all my twist drills with a lower clearance angle than standard. This
helps to prevent the drill from pulling itself into the work too quickly, with
often disastrous results. As far as speed and feed rate is concerned, I like
to have the drill going fairly quickly with a light application pressure. If
the drill is razer sharp it will fall through the poly like its cutting
butter. I usually cover the area over the hole to be drilled with masking tape
before drilling. This helps to prevent any risk of perimeter chip-out. When
I'm drilling lids for fitting rubber buffers, I run a couple of strips of wide
masking tape on the panel adjacent to where I'm planning to drill, to prevent
scratching and scuffing of the surface with the Portaline, which is the
drilling attachment I use for holding the drill square to the panel.</DIV>
<DIV><BR></DIV>
<DIV>While its easy to drill into polyester with low clearance angle drills, I
recommend that you drill or grind away a clearance-diameter of polyester, down
to the substrate, so that the mounting screws can't come into contact with the
polyester. Preventing the risk of a crack developing. Once you've drilled your
minor diameter hole for the mounting screws, you can cut away the polyester to
the substrate with a larger drill to ensure that there is good polyester
clearance from the outside diameter of the screw. This will prevent any risk
of a nasty stress crack running out from the screw hole at some future time.
Some caution is required when drilling away the poly to provide clearance,
since the larger drill, with no material at the drill centre for control, can
allow the drill to tear into the panel unless the feed pressure applied is
very light. Another approach might be to drill your hole clearance first,
being careful not to drill it too deep, then following it with the minor
diameter drill. I generally don't drill the clearance away first, because it
increases the risk of drilling the minor diameter hole off line. If you've got
some tungsten carbide grinding balls and a die grinder handy, using these can
be lot safer way of providing clearance for the screw after drilling the minor
diameter hole, without risk of tearing up a piece of polyester.</DIV>
<DIV><BR></DIV>
<DIV>Ron O.</DIV>
<DIV><BR></DIV>
<BLOCKQUOTE cite="" type="cite"><FONT face=Arial size=-1>Have a client that
wants the 9"x1" hinge installed on the music rack - it originally never had
one "</FONT></BLOCKQUOTE>
<BLOCKQUOTE cite="" type="cite"><FONT face=Arial size=-1>The piano has a
high gloss polyester finish along with some very fancy veneer on the music
shelf.</FONT></BLOCKQUOTE>
<BLOCKQUOTE cite="" type="cite"><FONT face=Arial size=-1>Drilling into poly
makes me a bit nervous - never did it before, expecially in such a visible
area of the piano -</FONT></BLOCKQUOTE>
<BLOCKQUOTE cite="" type="cite"><FONT face=Arial size=-1>Is there a
technique that someone uses to dimple the spot to drill so that the poly
will not split, or to prevent the dirll bit from wandering? Accuracy is
a must.</FONT></BLOCKQUOTE>
<BLOCKQUOTE cite="" type="cite"><FONT face=Arial
size=-1>Regards,</FONT></BLOCKQUOTE>
<BLOCKQUOTE cite="" type="cite"><FONT face=Arial size=-1>Gene
Nelson</FONT></BLOCKQUOTE>
<DIV><BR></DIV>
<DIV><BR></DIV><X-SIGSEP><PRE>--
</PRE></X-SIGSEP>
<DIV><FONT face="Times New Roman" color=#0000ff size=+1><B>OVERS PIANOS -
SYDNEY</B></FONT></DIV>
<DIV><FONT color=#000000><I> </I></FONT><FONT
color=#0000ff><I>Grand Piano Manufacturers</I></FONT><FONT
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<DIV><FONT color=#000000 size=-2><BR></FONT><FONT color=#000000>Web
http://overspianos.com.au</FONT></DIV>
<DIV><FONT
color=#000000>mailto:ron@overspianos.com.au<BR>_______________________</FONT></DIV></BLOCKQUOTE></BODY></HTML>