Originally Posted by xymotic
I'm installing some lights on the bottom of a 1" SS rail. I need to drill a few holes in a 1" SS rail. Is there a 'trick' to reliably find the center so each light isn't a few degrees off?
There are quite a few jigs available like this one from Sailrite
If you only have one or two holes to drill I'd make a jig like rhr1956 diagrammed.
To keep it simple just route out a one inch channel, take it out with a dado set or nibble it out with a table saw.
If you're not set up with woodworking tools you can make it by gluing pieces of plywood together.
Just remember to make the jig long enough that you can use a clamp to hold it in place.
A good tubing cutter will have a de-burring tool you can use to clean up any rough edges on the hole and some heat shrink tubing on the wires where they pass through the hole will prevent shorts.