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Originally Posted by jmr
That turned out very nicely, klh. I'm curious though, for the hole in the center, what did you use to make it? I found that when I drilled a hole in the cardstock it would affect the accuracy of the wheel (lines not lining up with other lines) but if I kept it simple and used a pushpin with cork on the reverse side, accuracy of the wheels wouldn't be affected.
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I drilled it very carefully. First I used an awl to poke a small hole at the centerpoint printed on each card. Then I drilled through at slow speed taking care to stay on the centerpoint. I think the key is taking your time (the same is true for cutting out the cards - I was never that good at cutting in kindergarten).
But you are right, there is a slight offset on a couple of the cards (< 1mm) that does affect the accuracy by a degree. If I had to do it over again (which I might if I build the US version for SH4), I would probably use a drill press and fasten the card to the bench before drilling.
I considered using a pushpin, but I preferred the nut/bolt option so that I could tighten it easily as it wears (I used a nylon locking nut).