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Originally Posted by sanddrag
Lasercutting or Waterjetting or CNC milling are the only real "professional grade" solutions. The only other alternative would be a hole saw but you will have lots of filing and sanding to do, it comes out ugly. Also, prepare to go through lots of hole saws.
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I disagree with your theoretical "professional grade" statement (not that perfection is required on FIRST robots). Check those 2" holes in the pics I linked earlier (I can take other pictures tomorrow, if you're not convinced). All done with a single hole-saw, deburred by hand, and then sanded with fine sandpaper. It looked/looks great.
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Also note the offset holes, like Holtzman mentioned earlier.
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We can help FIRST improve the system, but we can't just blame them and wait. - Siri [more] 
01-02-2005, 22:12
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