Drilling DIN socket hole

tjmouse

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I’m getting rid of my dash surround and hence my DIN socket so want to drill the spot BMW designed on the bodywork between the tank and the screen.

Questions:
Can I do this without taking the bodywork off the bike? Access seems easy enough so I expect I can but is there a reason not to?

What drill bit do I need? Do I need a specialist bit or can I use a standard bit set?

Any techniques to not ruin the plastic/paint? Progressively increase the hole in drilling? Guessing the old masking tape over the paint will help?

Your collective wisdom is appreciated :)
 
Use a step drill fella ...... and do it slowly!

ae235
 
As per Tunneruk's post ... I did what you're planning and looked into it - never used a step-bit before so bought a set of 3 at TK Maxx once and they are great/simple bits to work with!

As for getting the centre of the hole - feel your way around under the plastic where BMW have left the space and you'll feel there's metal framework for the beak down there (only thin) which could interfere with the nut which holds the auxiliary plug in place.

I used masking tape on the surface and, with a small square, transferred the measurements from the metal framework up to the masking take then worked out the centre.

Now, work out the diameter of the auxiliary socket and match that with the step-drill bit and mask that depth off knowing this is where you're going to stop pushing.

Finally - to make sure you've got the diameter right, test it on a bit of waste wood/metal/card to make sure the auxiliary socket fits.

Then ... have the bottle to go for it steady away...no rushing ... the blades on the bit will be very sharp if you're buying new :thumb2
 
I’ve done what you’re contemplating but decided to take the panel off to drill it. Before taking the panel off I marked it from underneath with a marker pen (coloured in the hole through the metal framework) before using a step drill as described. Beware, the drill cuts fast through soft plastic.
 
I’ve done what you’re contemplating but decided to take the panel off to drill it. Before taking the panel off I marked it from underneath with a marker pen (coloured in the hole through the metal framework) before using a step drill as described. Beware, the drill cuts fast through soft plastic.

Exactly what I did. There is no way to accurately drill the hole from above. You can start with a small ordinary drill but finish with the step drill. Drill from the outside to avoid burrs but as @Steve says, go carefully.

Mine carries a toggle switch that replaced the useless thing BMW fit for the Aux Headlights. The original switch now just keeps it's hole looking tidy.
 


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