I did use a drill press, and vice... problem was the bit having a slight wobble which caused issues when going through the support. I learned from the first peg and my 2nd peg turned out perfect after hollowing it out (and purchasing a new set of titanium drill bits :D).
I'm actually surprised you didn't use a drill press considering the professional results. Again, really good job... wish I would have seen this a month ago as I was starting my mini project. Here I was thinking I was being original with my 8mm LEDs... and to top it off we both have 07 white/silver bikes and were planning on doing the master cylinder thing... It's like we're getting the ideas from the same place. ;)
How did you get that brushed aluminum finish? Did you just use some sandpaper? If so, what grit did you use?
Man, I never would have thought that a drill press with a vise could have still been thrown off by the supports!
I was in your boat too. My second peg turned out darn near perfect in comparison to the first.
To get the brushed aluminum finish...
- Be careful when grinding off the reservoir guard and hook. Don't remove material below the surface of the peg's leg.
- Leaving a small "nub" where the guard and hook used to be, finish it off with a flat file.
- I used the coarse side of a sanding sponge. Sanding one direction only, in long controlled strokes that followed the curve of the peg.
The brushing really helps everything blend in nicely.
Good luck with your project! I think the 8mm LEDs are rad.