[sdiy] Re: [AH] Making holes in Aluminum?

[Andre Majorel]

On 2008-10-26 19:39 -0700, Kylee Kennedy wrote:

> Can anyone point me to a few webpages on how to make holes in an aluminum
> faceplate?
> I have a bunch of Frac Rack blank faceplates and I'm clueless. Something
> about a tap and carbide bits I believe.

A tap does not make a hole, it makes a thread. :-)

No carbide bits needed. Aluminium is a soft metal, any HSS bits
should do. Mark the spot with a centre punch. Start with a small
hole, say 2.5 mm and gradually work your way up from there. For
example, to make a 9 mm hole, you might want to use three bits :
2.5 mm, 5.5 mm and 9 mm. The diameters are not critical, it's
just an example.

  http://www.rapidonline.com/Tools-Fasteners-Production-Equipment/Hand-Tools/Punches-Rivets/Automatic-centre-punch/32193/kw/punch

If this is a large diameter hole (say > 5 mm) in thin sheet
metal (say <= 2 mm), a stepped bit will help a lot.  You'll see
why when you have tried making a 10 mm hole in 1 mm sheet metal
with a normal bit...

  http://www.rapidonline.com/Tools-Fasteners-Production-Equipment/Power-Tools/Drill-Bits/Multicut-step-drills/68134
  http://www.rapidonline.com/Tools-Fasteners-Production-Equipment/Power-Tools/Drill-Bits/Conical-drill/76430

Drilling metal is not about high rotation speeds : it's about
slow-to-medium speeds and applying pressure (one of the reasons
why a press is desirable). With cutting oil, you can drill
faster and the bits stay sharp longer.

-- 
André Majorel <URL:http://www.teaser.fr/~amajorel/>
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