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Discussion Starter #1
Common story: holes don't quite line up.

What's the best tool to help me reposition the mounting hole? Drill bits remove material too slowly to make any progress.

There has to be some hand tool or even something I can put in my roto tool or drill. I thought about wasting a soldering iron, but it would cause a build up of plastic and I'd then have to remove that, not fun nor good to inhale.

Suggestions on something I can pop down to Home Depot and buy right now?
 

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Dremel tools have a rotary bit that is used to cut out outlet holes in sheet rock. You just need a real strong steady hand, if the bit grabs it could walk and leave you with a damaged fairing.

You could also try a tapered round rasp file.

Why won't the drill bit work?
 

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Discussion Starter #3
The drill bit isn't chewing through the plastic. The hole is already there, I'm trying to elongate it by pressing against the side of the bit.
 

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maybe im not quite understanding the situation. pics might help, but a drill bit should cut through fairings like a hot knife to butter. i just put on a auctmarts kit and things lined up pretty well but i did need to bore out a few of the holes so bolts would fit through etc etc. i used a x-acto knife and it shaved out the holes in the abs pretty quickly.
 

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The drill bit isn't chewing through the plastic. The hole is already there, I'm trying to elongate it by pressing against the side of the bit.
The dremel bit I described will do exactly that. It's designed to cut laterally, rather than straight ahead like a drill bit.
 

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As Ian said, rotary files and a Dremel tool. I used to have a pneumatic pencil grinder that when used with the correct rotary file would cut through aluminum with ease and leave a smooth, clean hole, no de-burring necessary. It's all about feeds and speeds.

Similar to this:https://www.zoro.com/ingersoll-rand-air-pencil-grinder-industrial-60-000-rpm-7978/i/G2454085/?utm_term=C_mobile_Compressors&utm_source=bing&utm_medium=cpc&utm_campaign=PLA_US_BusinessComposition&utm_content=All%20Products&gclid=CPmemsOJotMCFdSJfgodrLoONw&gclsrc=ds

They are available much cheaper:

Astro Pneumatic Pencil-Style Die Grinder – 1/8In., Model# 218 | Air Grinders| Northern Tool + Equipment

You can use end mills such as these:

https://www.amazon.com/Konmison-Carbide-Engraving-3-175mm-Cutting/dp/B015WFYOK4/ref=pd_rhf_dp_s_cp_5?_encoding=UTF8&pd_rd_i=B015WFYOK4&pd_rd_r=G11V3Y5NPHVBTX2K1JJM&pd_rd_w=REYDV&pd_rd_wg=IlnP0&psc=1&refRID=G11V3Y5NPHVBTX2K1JJM

or these:

https://www.amazon.com/HQMaster-Carbide-Router-Acrylic-Hardwood/dp/B010NI39WO/ref=pd_cp_469_1?_encoding=UTF8&pd_rd_i=B010NI39WO&pd_rd_r=AVYVV5XARAAQXMPX43MS&pd_rd_w=mJ0cG&pd_rd_wg=m8hsZ&psc=1&refRID=AVYVV5XARAAQXMPX43MS

It should work with an 1/8" drill bit on plastic also, may just not leave as smooth a finish.
Slim, light and easy to maneuver. Easier to wield than heavier, bulkier Dremel tools, just maybe not as versatile around the house. Perfect for precision grinding though. Most people probably don't want to spend the $60 to fit $500 worth of plastics, but they can be used with any 1/8" shaft attachments. I know, I'm way over thinking it, I just miss having one around.
 

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Discussion Starter #10
This is DONE. The files helped, but I also ended up removing a lot of material in 2 cases by drilling pilot holes and then chiseling out the material. The file helped make fine adjustments. Visually as installed, its undetectable.
 

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I will indulge your bike porn.
Awesome......attachments that don't show up :(

Not your fault Jay, someone clicked when they should have toggled. Maybe the site will get with the program and find out why avatars and attachments aren't displaying for most members.

I'm sure they were good pics though.
 

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Discussion Starter #15
Can you click the attachment?
My UI defaulted to mobile version which shows attachments. Pics work fine when I use full version (for me).

Sorry no worky worky for everybody.
 

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Can you click the attachment?
My UI defaulted to mobile version which shows attachments. Pics work fine when I use full version (for me).

Sorry no worky worky for everybody.
No, it doesn't display. I can't see any attachments anymore.
 

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Heeza Y Zasch
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my BlackBerry sees his green rimstripes, gold rearsets, and pink grips just fine :hmm: :rotfl:
 

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I will indulge your bike porn.
Looks good, I hope no one was injured in the crash on your garage floor. Looks like Team Ducati taking each other out. Don't they put kickstands on bikes anymore?
 

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Purple grips, and it's my wife's bike. My daughter's bike has pink grips.
Don't hate guys, clearly his wife enjoyed the '80's! Purple and green were in, in some clicks. I'm kinda diggin' the other bike, one each pink grip, brake lever, brake caliper, freestyle peg and pedal and one green one. Rainbow stars and tiger stripes, pink tires, there's a lot going on there! :tu:
 
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