there are three secrets to making your own e-mag selector switch.
the first is the inner diamater(sp) of the screw hole.
this can be achived with a 1/8" drill bit
the second is the counter sink on the screw hole.
this is done with a 3/16" drill bit
the third is the hardest this is the width of the groove on the under side of the switch.
this can be found from the width of a 6" single cut bastard file. the width is perfect.
the quick directions for making one follow.
1. score one side of your metal with the file to get the width of the groove.
2. if you have a dremmel use this to create the groove itself. my suggestion is to cut the width of the groove without worrying about the depth untill the file can fit in the groove. use the file to flatten the bottom of the groove.
3. once the width of the groove is set use the 1/8" bit to to drill the first hole. do this with the groove up.
4. now with the groove down use the 3/16" bit to drill the counter sink. be very carfull to not go fully through the metal. drop the screw into the hole and make sure there is enough of the screw to catch the reciever.
5. once this is done either cut (with the dremmel) or file down the wings of the groove to the right length. test with the reciever to get a feel for the right depth.
6. clean it up. do what ever else you want to the shape of the switch but leave the screw side of the switch alone as it should be where you want it. if you want to you can shorten the top side of the switch at the screw but test frequently with the screw to make sure you aren't going to deep.
this took me about an hour and a half to finish it down from a 1/4" square steel stock bar. a vise is needed but almost anything should work. polishing can be done with mothers mag polish and steel wool or what ever other method you wish but it is not needed. good luck and happy tinkering.
the first is the inner diamater(sp) of the screw hole.
this can be achived with a 1/8" drill bit
the second is the counter sink on the screw hole.
this is done with a 3/16" drill bit
the third is the hardest this is the width of the groove on the under side of the switch.
this can be found from the width of a 6" single cut bastard file. the width is perfect.
the quick directions for making one follow.
1. score one side of your metal with the file to get the width of the groove.
2. if you have a dremmel use this to create the groove itself. my suggestion is to cut the width of the groove without worrying about the depth untill the file can fit in the groove. use the file to flatten the bottom of the groove.
3. once the width of the groove is set use the 1/8" bit to to drill the first hole. do this with the groove up.
4. now with the groove down use the 3/16" bit to drill the counter sink. be very carfull to not go fully through the metal. drop the screw into the hole and make sure there is enough of the screw to catch the reciever.
5. once this is done either cut (with the dremmel) or file down the wings of the groove to the right length. test with the reciever to get a feel for the right depth.
6. clean it up. do what ever else you want to the shape of the switch but leave the screw side of the switch alone as it should be where you want it. if you want to you can shorten the top side of the switch at the screw but test frequently with the screw to make sure you aren't going to deep.
this took me about an hour and a half to finish it down from a 1/4" square steel stock bar. a vise is needed but almost anything should work. polishing can be done with mothers mag polish and steel wool or what ever other method you wish but it is not needed. good luck and happy tinkering.