(08-21-2012) Holoprojector Holes

I have been dreading cutting the inner dome ever since I got it.  The worst part for me was making that first cut.  Here is how I cut the HP holes in my dome...

 Step 1:  After deciding where you want the holes and marking the hole and the center point, make a rough cut inside of the marks.  I drilled a hole in the center and then used a hole cutter (utterly useless - I won't be using it again, maybe next time I'll just use a hole saw) and a dremel with cutting disks (much better results - but hard to control).

Step 2:  Use a D shaped file and file until you think you're close.  Then test fit your HP housing to see how it fits.  I found that once I was close the HP housing would pivot on the narrowest part of the hole and I could file these areas until I had a perfectly round HP hole. 

Step 3:  Once a good fit is achieved and the hp housing sits flat inside the inner dome, put on the outer dome and look at your work.  Drink a cold one in celebration of a job (well?) done.

After doing the front and rear holoprojector holes I'm far less worried about the remaining holes.  I want to mount the two HPs to get the domes aligned before making any further cuts.  Hopefully this will help in making sure everything is lined up as well as I can get it.  I don't think the remaining holes will be too bad, except for the rear PSI.