Drilling precise grids without a CNC machine can be tough to pull off. [Ookseer] has come up with a nifty method for dilling aligned holes with a drill press. He uses a right-angle jig on a Dremel drill press with stacks of business cards as spacers. The same number of cards is added between the substrate and the jig to space each new hole evenly. This method comes in handy when drilling grids in an enclosure for speakers, temperature sensors, or for an aesthetically pleasing design.

[Contraptionmaker] ran into a problem when putting plastic insulation over his windows during the winter. When you cover the windows from the inside to prevent drafts, your access to the stick that opens the blinds is cut off. His solution was to build an automatic blind opener from a cordless drill. He started with some motors he had around the house, but none of them were strong enough. The final solution was a $10 Black & Decker drill. After removing the handle and trigger to extend it, he made a simple wall mount for it. You may notice him soldering some batteries into it, in his directions. Those are just for backup, in case the power goes out. You can see a video of it in action after the break. If you want something triggered by an alarm, or for a different type of blind, we may be able to help you out.

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A decent drill press is a crucial tool for an electronics lab. We use our drill press to make holes in our own circuit boards, and tap or break traces on existing circuit boards. We’ve used a lot of tools to drill circuit boards — power drills, power drills in “drill press stands”, and high-speed rotary tools — but when we started doing projects on a schedule, it was time for something more reliable.

We first spotted the Proxxon TBM115/TBM220 drill press in the window of a local shop.  Its tiny size and adjustable speed seemed ideal for drilling circuit boards. At $200, this is one of the pricier tools in our lab, but quality bearings and smooth drilling action aren’t cheap.  Read about our experience with this tool below the break.

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[Alexander.m] shows us how to do a major overhaul on a cordless drill, replacing pretty much everything but the case. He needed some more power, but found the price tag of the bigger drills to be prohibitive. He opted for a more hacked together approach and used a  24 volt 1.4 hp hobby motor as a drive. He had to make a custom enclosure for the batteries too. The final result may not be the prettiest thing in the world, with that giant battery pack on the bottom, but it probably gets the job done pretty well and cost less than half of what a new one would have.

[yellowduck] took some fantastic initiative with this home made PCB drill press. Many people have a rotary tool already. Just add some scrap wood and four hinges. The drill press isn’t perfect; it pivots a little as it lowers. This shouldn’t be a problem for drilling printed circuit boards though. The PCB should be thin enough for the pivot to have little effect. After some test runs, he added a lamp for better lighting and intends to add a return spring and foot switch. It’s definitely a better solution than drilling multiple holes with a hand drill.

[Richard] took another shot at his battery powered tesla coils. He sent in his latest hand held plasma gun. He modified his battery powered tesla coil to work as a handheld. He added a large copper pad to the drill handle to couple the RF ground to the human torch holding it.. Sure, we’ve seen plenty of tesla lately, but who here wouldn’t want one? (Maybe the guy in the server room…)

All the parts needed are listed – just be sure you fully understand everything before you get into this one.