Postmodern Sysadmin

A blog about servers and junk

Ahoy! Holes!

The next step in our Lasertag construction project is the preperation of the boxes for our components. We have decided to put all of the electronics in a backpack. But the backpack will need some I/O. We need a rj-45 for the gun, two for the arm-band, a usb for the key, and a hole for the power switch and power plug. How do we do it? We need square holes… Well, the best and nicest way I can think to do it is to use a little thing called a roto-zip bit. I bought 5 of them at Home Depot for a few dollars. Luckily Karl has a drill press: The Drill Press Rig The pictures mostly speak for themselves. Basically we used a cardstock template:

Using Template

Then spraypainted the negative:

Spraypaint Negative

And Routed!

Route it Out

We will have to use a flat file to make some holes perfect:

We are going to have to file

But the USB port worked great (It actually looks better in real life)!

Usb fits nice

I can’t think of a better way to do this in plastic. And the results are nice, with patience and hard work. We have done 10 boxes like this.

All thanks to this one bit: The miracle tool

Who needs a CNC machine when you have steady hands Karl? (Video)