Wednesday, June 18, 2008

Cutting a circle in a dome

For those of you that have never seen it before elsewhere, this is how to cut a circle in a dome the cheap way.

After checking all your trace out lines a few times take a drill with a sharp bit and drill along the inside of your traced area.

Next carefully wiggle your drill side to side till it connects a few adjacent holes together in a few areas. Then take a hacksaw blade and cut alone the dotted lines.

Take the curved side of a large rasp and file till you are a hair past you layout lines.
Flip the dome over and use a finishing rasp to take off all the burrs.
As you can see the holoprojector ring fits perfectly.

1 comment:

Paul said...

You're a very brave man, I'd be scared to death drilling one hole outside that circle! You're making good progress, wtg!