Drilling the side cover ?

Johnny Y · 06-14-2016, 02:51 AM

I'm thinking of installing a waterproof switch for my PCV on the backside of the right side cover. Will the drill cut a nice clean hole or am I taking a chance on shattering the plastic ?

**canuckrider** · 06-14-2016, 11:11 AM

How big a hole do you need for the switch? I would start with a small pilot hole and gradually work my way up to the size of hole needed. I would think that if you have a decent set of sharp drill bits you should be okay and will not crack the plastic.

**JD Hog** · 06-14-2016, 11:21 AM

I just did this on my dash a week ago and like canuckrider said start small and work up from there. No problems doing this for me.

cactusjack · 06-14-2016, 11:30 AM

I would use one of those "stepped" multisize drill bits. A twist bit will many times not produce a clean, round hole in plastic.

Johnny Y · 06-14-2016, 11:35 AM

Looks like I need a 1/2" hole. On Amazon its CT126- LS-B.

**JD Hog** · 06-14-2016, 12:23 PM

Quote:

Originally Posted by Johnny Y

Looks like I need a 1/2" hole. On Amazon its CT126- LS-B.

Are you sure about a 1/2" hole? Under the "Product Description" section it says a 3/8" hole.

https://www.amazon.com/Core-Tools-CT...=1&*entries*=0

rick6375 · 06-14-2016, 01:52 PM

Dont do it on cold plastic, best that its warmer, less chance of cracking since it will be softer. Maybe leave it in the sun a 1/2 hour or so on a hot day. Drilled the side cover on my 800 for a volume control for me speaker, no problem.

Gypsy Dragon · 06-14-2016, 01:57 PM

Quote:

Originally Posted by cactusjack

I would use one of those "stepped" multisize drill bits. A twist bit will many times not produce a clean, round hole in plastic.

This is the best way. Drill a small pilot hole, then use an stepped, metal bit to drill the hole to 1/2". This was how i drilled my holes for the KQR hardware, and it left a very clean hole.

waboritas007 · 06-14-2016, 07:49 PM

you might try using a piece of paper/masking tape and run the drill in reverse. It will take longer but will not be as aggressive thus lowering the odds of fracturing the plastic. Hope this helps.

dshelly · 06-14-2016, 08:16 PM

Use a single flute countersink the size of the hole you need. It will drill a nice clean hole without breaking your plastic. I do this all the time on plastic.

Snake Ranch · 06-15-2016, 04:50 AM

Quote:

Originally Posted by dshelly

Use a single flute countersink the size of the hole you need. It will drill a nice clean hole without breaking your plastic. I do this all the time on plastic.

Plus 2. Also keep your drill rpm's low, and a little alcohol will lube the plastic and keep it from sticking.

Demolition Man · 06-15-2016, 10:44 AM

Why not, placed a 12V outlet in the right side cover - also useable to charge the battery with a trickle charger during winter.

Cu,
Sven

06-14-2016, 02:51 AM	#1
Johnny Y Member Join Date: Jul 2015 Location: S.E.WI. Posts: 159	Drilling the side cover ? I'm thinking of installing a waterproof switch for my PCV on the backside of the right side cover. Will the drill cut a nice clean hole or am I taking a chance on shattering the plastic ? __________________ Johnny Y PCV. Chucksters B.A.K. , D&D slip-ons. Login or Register to Remove Ads
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06-14-2016, 11:11 AM	#2
canuckrider Join Date: Jun 2010 Location: Okotoks, AB, Canada Posts: 1,088	How big a hole do you need for the switch? I would start with a small pilot hole and gradually work my way up to the size of hole needed. I would think that if you have a decent set of sharp drill bits you should be okay and will not crack the plastic. __________________ "Sun on my face, wind in my hair, sound of my bike in my ears and peace in my soul..." VBA Member #01514 2008 "Ultra" Nomad 1600, Candy Plasma Blue
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06-14-2016, 11:21 AM	#3
JD Hog Join Date: Mar 2014 Location: Placerville, CA Posts: 2,948	I just did this on my dash a week ago and like canuckrider said start small and work up from there. No problems doing this for me. __________________ Jim Diebolt 2015 Vulcan 1700 Voyager ABS The Black Kaw 2005 Vulcan Nomad Sold 2006 Honda 1800 VTX (Freebie) Sold 2008 Harley Ultra Classic Sold 2001 Harley Ultra Classic Sold Hangtown, Kalifornia VBA #2625
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06-14-2016, 11:30 AM	#4
cactusjack Mega-Contributor Join Date: Sep 2007 Location: Where it doesn't snow...ever! Posts: 21,926	I would use one of those "stepped" multisize drill bits. A twist bit will many times not produce a clean, round hole in plastic. __________________ Scott "Cactusjack" Hanks VBA #00105 H.O.G. #4250060 2011 H-D Ultra Limited 103ci :: 2011 HD Electra Glide Ultra Limited w/Stage 1 :: Rallies: Mesquite '08\|Custer '09\|Cortez '10\|Crescent City '11\|Kanab '12\|Antlers '12\|Estes Park '13\|Antlers '13\|Orofino '14\|The Dalles '17
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06-14-2016, 11:35 AM	#5
Johnny Y Member Join Date: Jul 2015 Location: S.E.WI. Posts: 159	Looks like I need a 1/2" hole. On Amazon its CT126- LS-B. __________________ Johnny Y PCV. Chucksters B.A.K. , D&D slip-ons. Login or Register to Remove Ads
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06-14-2016, 01:52 PM	#7
rick6375 Member Join Date: Dec 2013 Location: New Castle, In. Posts: 365	Dont do it on cold plastic, best that its warmer, less chance of cracking since it will be softer. Maybe leave it in the sun a 1/2 hour or so on a hot day. Drilled the side cover on my 800 for a volume control for me speaker, no problem. __________________ 2005 800 Classic 2012 Voyager ABS
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06-14-2016, 07:49 PM	#9
waboritas007 Jr. Member Join Date: Feb 2016 Location: Metro Atlanta Posts: 6	you might try using a piece of paper/masking tape and run the drill in reverse. It will take longer but will not be as aggressive thus lowering the odds of fracturing the plastic. Hope this helps.
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06-14-2016, 08:16 PM	#10
dshelly Sr. Member Join Date: Mar 2012 Location: Belgrade, MT Posts: 2,824	Use a single flute countersink the size of the hole you need. It will drill a nice clean hole without breaking your plastic. I do this all the time on plastic. __________________ Dave "(dshelly)" Shellenberger 2014 Harley Ultra Classic 2007 1600 Nomad (Black) Shellenberger Machine Belgrade, MT Various Bagger Member (Harley Chapter) VBA # 2395
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06-15-2016, 10:44 AM	#12
Demolition Man Member Join Date: Mar 2016 Location: Hannover, Germany Posts: 380	Why not, placed a 12V outlet in the right side cover - also useable to charge the battery with a trickle charger during winter. Cu, Sven __________________ "Democracy is two wolves and a lamb deciding what to have for dinner. Liberty is a well-armed lamb." - Benjamin Franklin MY LIFE - MY RULES ! 2018 Indian Roadmaster
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