Stomp box update:
Drilling has been completed. We had to stop fitting components in the box because it's school tomorrow and bedtime loomed.
I concur with Cerebus' "porridge" (or what it was) verdict regarding the alloy Hammond are using. It is quite soft. But, using 2mm pilot spiral drill (Gühring, IIRC) into punch marks and then step drilling to 12mm for the footswitch gave a perfect hole with smooth edges. No deburring needed at all. In comparison, the smaller holes for phone jacks, pots, toggles, and DC jack, varying between 4,5mm and 9mm, were all drilled with various spiral drills, some SKF, some noname, some Walter "Titex", and gave sharper edges that required a few turns with the Noga deburrer, but all were nicely circular and to dimension.
All of this of course was in the Ixxion drill press, a "boutique tiny" tabletop model, three-phase of course. Mostly low rpms; I think the step drill went at about 480rpm, and the others perhaps 850.
I'm going to fit the PCB between blocks of styrofoam and also insulate it with a heavy duty plastic sheet, because the toggle switches are protruding quite a bit into the box.
I still have 9 PCB's left, so am contemplating selling component kits online. I've got a start on a building instructions document; praising the virtues of a large TE collection:
Measurement instruments: You must have the ability to
measure AC and DC Volts, resistance and DC current. A digital
multimeter with 3200 counts display will probably be OK.
Verification of function will be considerably easier if you can
generate tone, look at tone, measure frequency, and check capacitance
and resistance. I collect test equipment, and I used 2 multimeters,
two oscilloscopes, a distortion analyser, a low-distortion tone
generator, a DC clamp Ampère meter, a frequency counter, and a LCR
meter.
If you're getting only one instrument beyond the multimeter,
try for the scope. Literally any scope in existence will be good
enough: A 10MHz analog scope will do. One channel is OK.
As third instrument I would suggest a tone generator. It should
at least do sine waves at audio frequency, and able to have an
output level of about 100mV.