Sometimes you have to put a piece of tube through a plate. When the tube is round, there isn't any problem. You just need to drill a hole large enough to fit the tube. When the tube is square, however, you run in to problems.
See, mill bits and drill bits are round. This means that no matter how small a bit you use to mill out a square hole, the corner of that hole will always be rounded. However, there is a workaround.
How to mill a square hole:
- Drill a hole (I usually use a 1/4" bit) at each of the four corners of the square
- Drill a hole somewhere inside the square large enough to allow the mill bit through
- Switch to whatever size mill bit you think you need
- Mill from the hole in the center of the square to one of the edges of the square you want.
- Continue milling around the edges of the square
If done correctly, this method will create a hole with straight edges but no real corners. Congratulations, you can now fit your piece of square tube in the hole without having to worry about filing the corners square.
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