Here's exactly what tools I used for a precise build on these gauntlets. I'm sure there's always room for improvision to cut down on the number of drill bits & tools used.
Here's a list of the specific tools I used:
- 1/16 drill bit: Tap out punch holes in large hinge to release pin.
- 3/32 -6" drill bit: Clean out the inside of the hinge links of Home Depot hinge to be used for the pin closure.
- 3/32 drill bit: Pre-drill holes in flamethrower, missile, whipcord, and hose attachment for the set screws used to attach those parts to the shells.
- 1/8 drill bit: Holes for the 2 mini-darts.
- 11/66 drill bit: Holes in shells for set screws used to attach parts.
- 5/32 drill bit: Pre-drill hole for hose attachment on whipcord. Drill holes for the 4 aluminum darts.
- 3/16 or 7/32 drill bit: Holes for min-toggle switches.
- 17/64 or 9/32 drill bit: Holes for push buttons on flamethrower.
- 5/16 drill bit: Hole for Halo_1 LED.
- 21/64 drill bit: Hole for Dark-Side whipcord dart. Pre-drill holes for hose attachments on flamethrower.
- 3/8" drill bit: Holes for flamethrower nozzles.
- 1 1/8" Freud Percision Shear Forstner drill bit (#PB-008 ) to hollow out flamethrower.
- Reinforced Cut-off Wheel for Dremel (#426) to trim recessed areas on shells for Dark-Side hinge. General trimming around edges of shells.
- 60 Grit Sanding Band for Dremel (#408 ) for general trimming around edges of shells. Clean out clearance areas for toggle switches, mini darts, darts, LED, and slider switch.
- MultiPurpose Cutting Bit for Dremel (#561) to drill and clean out oblong hole for slider switch.
- 1/8-27 NPT tap: Thread pre-drill holes for hose attachments on flamethrower.
- 3/4" tape: Mark edge of recessed areas for Dark-Side hinge.
- Satellite City Special T CA glue: Glue hinge to shells.
I also used various shop tools like a cordless drill, drill press, Dremel, exacto knife, 220, 400, and 600 grit sandpaper, Krylong Grey Primer(in my opinon best available in a spray can for this kind of stuff).