This photo shows before I started with the holes marked out. Notice that the area marked is smaller than what the hole will actually be. This is just to help me start the punch. Since the punch has a bit of a taper, it opens up the hole some. After that, the I use a drift to open the hole further to its final size.
I was really happy with the results. When I actually stack the posts, the holes line up perfectly. I know that my first attempt at the clock was not this close to matching. Part of the reason I decided to start from scratch was so I could go back and correct some of my previous faulty work. I know nothing is perfect but since this is a mechanical contraption, I need to be as close as possible.
This photo shows the result of today's work. It took about 90 minutes to mark and punch all 4 holes. I will do a bit of cleanup with a file but nothing major. Also, the lengths (at the top) are not perfectly matched. That is because there will be some cutting work up there before I am done.
