Embedding A Switch in Plywood

[Neilly]

I have a switch which I'm trying to put into a sheet of plywood (I thing around 5mm).
The switch is a missile style toggle switch (look on ebay if you're not sure), and it has a cover over it. I need the switch itself to be poking through the plywood, but the mechanism underneath has to stay on the other side. I tried using a spade bit to put a hole in, which worked well as the switch fitted through snugly, but the switch sits on a threaded section, which needs to be poking out too, as that's where the cover is screwed on. If you look at a picture of that style switch online, you'll see the part I mean. So is there any way to put just the threaded part through the wood, leaving the body on the other side? Oh and by the way, I have no power tools except a drill and a jigsaw. Thanks

 

[Rorschach]

Sounds like to need to thin out that area of the plywood to allow the threaded portion through, these kinds of switches are usually installed on much thinner sheet metal.
A router is the most efficient tool for the job but for just one then a sharp chisel and a steady hand will do the job just fine.

 

[oakmitre]

Making square cavities in plywood is not difficult.

Provided you can drill square through the wood, and you use a backer board on the front to prevent tearout.

Draw the switch body sized rectangle on the back of the plywood ( possibly 1mm larger to allow for error) around the hole you have drilled.

Using a scalpel or pointy craft knife and light pressure, score around the perimeter of the rectangle you have drawn.

Keep scoring around until you reach the glue line of the first layer.

Insert a stiff knife / small flat head screwdriver into the drill hole and into the glue line of the first plywood layer, push and gently twist. A small piece of wood will break away until it reaches the rectangle you have scored / cut. Go all around the edge.

Repeat until you get to the last ( or next to last in the case of hardwood faced ply - the final veneer is very thin ).

If the last layer is too thick, IE not enough switch screw thread pokes through to catch on the nut. Then make a close together lattice of scorelines, (like crosshatching) with your scalpel and then try to rake them out.

It may be easier (but time consuming) at this stage to use something abrasive to thin the bottom layer, like a piece or coarse sandpaper glued to the end of a dowel.

 

[Adam9453]

Drill a larger hole from the back but don't go all the way through. Then drill the smaller hole for the switch threaded section to fit through.
Should be the easiest way given the tools you have available

 

[Benchwayze]

If you want the threaded portion to project, so the retaining nut and washer are on the shown surface, use a forstner bit from the back to form a 'well', that can take the switch-body. Then drill the correct sized hole from the front to get a clean hole, which will allow the threaded portion through. That's how I mounted these kinds of switches in an old Mini I once tarted up.

That's if you mean what I mean by 'toggle-switch'.

https://uk.search.yahoo.com/search?p=to ... =yfp-t-903
Yes?
Or:

https://uk.search.yahoo.com/search;_ylt ... =yfp-t-903

HTH.

Oooops... Like Adam said. Sorry Adam. But that's what I meant! :lol: