question about mounting things in metal box with backplane

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I think the backplane was just regular steel, my main problem was trying to use the Klein triple-tap. But perhaps I need better drill bits too. I don't think I could have even drilled the holes without tapping within 15 minutes, the way I was doing it. I used the smallest bit 1/16" to drill all the way through the steel, so that the hole placement would be as accurate as possible. Then I used the 9/64 (I think) to drill a little over halfway through, then turned the sheet over and drilled the rest of the way from the other side. I drilled from both sides to avoid burrs of metal sticking out. I probably should have used a bigger drill bit before the tap, because if I recall correctly, I actually tapped them out to 8-32 first, then 10-32. That's an extra step I shouldn't have done.
Mark your holes (pencil, marker, etc...) and center punch. Drill with an 1/8" pilot. Step up to 5/32" to pilot for 10-32. Before tapping, use a much larger drill (3/8" or so... whatever is sharpest) and do a LIGHT chamfer on both sides of the subpanel to remove any burrs. Again... go lightly with the large drill bit - you just want to spin it to remove any burrs. Add some tapping oil (3-in-1 works in a pinch) and run the 10-32 tap through with a drill. High speed is better than low speed - less time to wobble the drill and break the tap. Reverse the drill to get the tap out. Repeat. It really shouldn't take you more than 15 minutes to do a dozen mounting holes.
 
Tools to make the work faster, easier and more precise.

National fine tap and drill index these come in sets or individual pieces there are small indexes that only go up to 1/4-20 ideal for panel building use. You can find them at a machinist tool supply near you.


A spotter punch set is also handy for accurately locating hole centers for your parts.


Then get yourself a can of tap magic cutting fluid.


Use the drills and taps in a slow speed drill with plenty of cutting fluid and leave the chuck not fully tightened on the taps to allow them to slip slightly instead of breaking until you get the hang of using them under power.
 
If you are going to buy a tap set for this type of work, I strongly recommend getting a set with two flute tapes instead of the traditional 4 flute ones.
The work much better, especially if you are using them in a drill motor.
 
This drill tap set from Greenlee works great, its fast and easy to use.
Use with tapping oil, the 6/32 are (as you might expect) easy to break.
I had a working set and an a second case with 2 of each tap. Greenlee sells the taps individually
I have tapped hundreds of holes (not with the same tap!) with them.
I also used a spring loaded center punch

What I don't like to see is "self tappers" as they hard to remove
In control panels, nearly all the components were DIN rail mounted.
 
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