This is a portion of my CNC motion control board assembly documentation.

CNC Controller Motion Board AC Installation (Rev. D)

The power plug, fuse, and switch are installed in the following steps:

The power plug is Jameco 147109. It is placed in the corner of pieceo of paper with a little paper left around the edge.
Using a pencil, the outline is traced.
Using scisors, the piece of paper is cut out leaving about an 1/8" round the traced outline.
In fact, the hole to be nibbled needs to be smaller than the traced outline. Using a ruller, I marked off a boundary from the traced outline. It is better to be too small than too large.
Using a utility knife, the inside border is cut out.
The template is taped to the box. This time I made doubly sure that it would not get too close to a transformer leg.
Getting ready to drill the starter hole for the nibbler.
The head of the nibbler is pretty big, so a pretty big drill hole is required.
The resulting hole is big enough.
After the hole is nibbled out, the paper template is removed. As I was getting close to the template edges, I continually tried fitting the plug in to make sure that the hole I nibbled out was not too big.
Afterwards, the plug is pushed in and snaps right in. There is a small amount of play afterwards (say 1/32"), but not enough to matter.
I cut a square of paper that covers the remaining corner of the box.
The square is taped down.
The fuse holder is Jameco 120993 and the power switch is Jameco 76232. They are placed on the paper square in the desired locations. A pencil is used to trace the outlines.
Using my ever trusty awl, I place dimples where I want to drill the two holes.
The fuse holder diameter is measured to be larger than the largest drill in my drill box (1/2".) Bummer!
So, I use the 1/2" drill and drill the fuse holder hole.
I peel back the paper square since it is not needed anymore.
Using a rotary file mounted in the drill press the 1/2" hole is enlarged. A circular motion is used to enlarge the hole in all directions at once. I kept enlarging the hole a little, and test fitting the fuse holder. I had the hole "just right" and then I slipped up when the drill was spinning down gouged out a much oblong hole that is significantly largere than necessary. Next time I will let the bit spin all the way down before touching the box.
The switch is measured to be about 1/2" in diameter.
Using the same drill bit as before, the hole is set up on the drill press.
The hole is drilled.
Finally, both the fuse holder and switch are installed. So far, my mistakes have been small enought so that they are not particularly visible.

	The power plug is Jameco 147109. It is placed in the corner of pieceo of paper with a little paper left around the edge.
	Using a pencil, the outline is traced.
	Using scisors, the piece of paper is cut out leaving about an 1/8" round the traced outline.
	In fact, the hole to be nibbled needs to be smaller than the traced outline. Using a ruller, I marked off a boundary from the traced outline. It is better to be too small than too large.
	Using a utility knife, the inside border is cut out.
	The template is taped to the box. This time I made doubly sure that it would not get too close to a transformer leg.
	Getting ready to drill the starter hole for the nibbler.
	The head of the nibbler is pretty big, so a pretty big drill hole is required.
	The resulting hole is big enough.
	After the hole is nibbled out, the paper template is removed. As I was getting close to the template edges, I continually tried fitting the plug in to make sure that the hole I nibbled out was not too big.
	Afterwards, the plug is pushed in and snaps right in. There is a small amount of play afterwards (say 1/32"), but not enough to matter.
	I cut a square of paper that covers the remaining corner of the box.
	The square is taped down.
	The fuse holder is Jameco 120993 and the power switch is Jameco 76232. They are placed on the paper square in the desired locations. A pencil is used to trace the outlines.
	Using my ever trusty awl, I place dimples where I want to drill the two holes.
	The fuse holder diameter is measured to be larger than the largest drill in my drill box (1/2".) Bummer!
	So, I use the 1/2" drill and drill the fuse holder hole.
	I peel back the paper square since it is not needed anymore.
	Using a rotary file mounted in the drill press the 1/2" hole is enlarged. A circular motion is used to enlarge the hole in all directions at once. I kept enlarging the hole a little, and test fitting the fuse holder. I had the hole "just right" and then I slipped up when the drill was spinning down gouged out a much oblong hole that is significantly largere than necessary. Next time I will let the bit spin all the way down before touching the box.
	The switch is measured to be about 1/2" in diameter.
	Using the same drill bit as before, the hole is set up on the drill press.
	The hole is drilled.
	Finally, both the fuse holder and switch are installed. So far, my mistakes have been small enought so that they are not particularly visible.