I looked at some of the videos and wasn't all that impressed. On one, when he cut out a window, he used cheap looking U-channel molding to cover up the raggedy edges he left from poor cutting and filing techniques. Had he used a straightedge to guide the jigsaw on the long cuts, they would have been a lot cleaner and easier to file (once he learns to anchor or clamp the piece, properly support it, use the proper file, and use both hands on the file), eliminating the need to hide the poor work (a clean edge with no cheap looking molding would have looked far more professional; that molding will shrink over time and leave gaps at the corners). A finer blade in the jigsaw (24 or 36 TPI, for example) would have reduced the amount of filing needed after cutting. Deburring tools are faster, do a better job at removing burrs than a file, and aren't expensive.
That shop needs to invest in a set or two of sheet metal drill bits. Sheet metal bits drill a much cleaner looking (less burr) and rounder hole than a conventional twist drill bit. A DYIer can always cut costs by buying only the sizes needed as needed so not doing so to save costs wasn't warranted in the video. For that matter, if they knew what they were doing, regrinding a conventional twist drill bit to a sheet metal profile isn't that difficult (my Daddy showed me how when I was a kid so it can't be that hard). Backing up sheetmetal with a wood block or, even better, inverting the case onto a sacrificial wood surface and drilling from the inside.
Hole saws are expensive but can often be rented.
Step drills (such as the Unibits) aren't too expensive, give nice round holes in sheet metal, don't need backing up, and can also be used for deburring the holes on all but the largest hole size of the bit. Their downside is a limited selection of hole sizes available (usually 1/6" to 1/8" increments). Even el cheapos from Harbor Freight work great for occasional use and are inexpensive.
He didn't even know the proper names of many of his tools. Examples: vertical saw for bandsaw, measuring square instead of combination square, rounded-side hand file instead of half-round file (it appeared to be a mill-******* double cut).
In the one video where he cut a window in a side panel and used square corners to because of existing holes from a removed logo, he could have opted to use small radius corners without dropping the lower by very much. All that was needed was to increase the size of the one hole at the corner by moving the hole down and left so the side of the window didn't change. A Dremel bit would have worked best for that since all that was needed was to establish the radius of the corner of the window. A drill bit with the same radius would work best for the other three corners. Then a jigsaw could have been used to make the straight cuts (using a straight edge to guide the saw instead of freehanding it to ensure a straighter line that would have required more filing to clean up). That small of a radius wouldn't have allowed him to use the U-channel molding but, if he made clean cuts and dressed them properly, he wouldn't need it.
Edit: after some of the posts I've seen here go uncensored, I can't believe ******* got censored. It is a legitimate term used to descibe the coarseness of a file. The censored word is synonymous with being of a so called illegitimate birth. Yeesh!
Thanks
