New Member-Drilling Square Holes in Metal

**budbuc** · Mar 12, 2016, 08:13 PM

Hi, my name is Bud Buchanan, Townsend, TN in Smokey Mtns. I found this site about a month ago I guess, and have found much help. I am mostly a DIY'er, because I can't afford to buy the tools I need. I am 73 yrs. old on a set income and don't plan on using tools to go into business, just fix things around the house. At present I am working at building a Pedal Steel Guitar that has 5/16" square shafts for the bell cranks. I need to drill a bunch of square holes, so I need help. Thanks to those who post new "homemade tools" and those that run this website. Good Luck to all....Bud

**Jon** · Mar 12, 2016, 08:23 PM

Hi budbuc - welcome to HomemadeTools.net

Post some pics of the pedal steel guitar if you have any, I'm sure people would like to take a look.

For the square hole job, I would suggest posting a new discussion in the Tools in Progress subforum (or click "Build Help" above), and I'm sure you'll get some good ideas.

**Jon** · Mar 12, 2016, 11:02 PM

Looks like you didn't have to wait long! Frank S to the rescue: poor man's square broach

**kbalch** · Mar 13, 2016, 02:51 PM

Hi Bud,

Welcome!

Do you play the pedal steel, too? I've always liked that instrument.

What's next up on your build list?

Ken

**Jonny** · Jul 21, 2016, 05:51 PM

Hi
Fileing a square hole is a steel boss probably isn't as bad as you might think. The key is GOOD Sharp (read new) files. Old dull files are frustrating at best.
This is a great exercise in craftsmanship. First, with a new file, cut on only the push stroke, then lift and repeat. after a few strokes remove the file from the work and brush it clean with your hand or better yet a file card following the direction of the teeth. then proceed patiently and carefully. with good tools and some practice you can file way more than you ever thought you could.
Jonny