Reducing the size of a hole

[ckrtech]

What a fun question to ask.

I have a spot where I want to place my power switch and it is slightly too big. It is big enough for the power switch to fit, but too big for the small screws to get a full wall around the holes.



That aluminum is going to have an adhesive layer over it, so aesthetics are rather unimportant so long as the outer surface is relatively smooth.

I think I have several options here, but I thought I would ask for recommendations before I try something out.

[jjhammerstein]

What a fun question to ask.

I have a spot where I want to place my power switch and it is slightly too big. It is big enough for the power switch to fit, but too big for the small screws to get a full wall around the holes.



That aluminum is going to have an adhesive layer over it, so aesthetics are rather unimportant so long as the outer surface is relatively smooth.

I think I have several options here, but I thought I would ask for recommendations before I try something out.

If that's aluminum, you should be able to drill just the way it is.
drill so that you have a hairline wall on the inside edges. and force the screws in.
It'll bend the thin walls out, and should work pretty well.

Or, mount the switch onto a separate plate, and then mount that on the inside of the case so the switch comes through the hole.

[Kurt_]

Use bondo. Forget about screws, for something like that, get some bondo putty. NOT the "glazing and spot putty", but the two part epoxy roll stuff.

Kind of like this stuff:



It always seems to be green on the outside.