MOTM

For some time I have been using an aid when drilling holes in aluminum but 
don't recall seeing this mentioned on the list.  I'm probably the last one to 
figure this out, but in case I'm not, let me introduce you to a cutting fluid 
called "Tap Magic".  This cutting fluid is fantastic stuff.  It will extend 
the life of your drill bits many times and the holes you drill in aluminum 
will simply amaze you.  No, this is not blatant advertising on my part.  I'm 
just a very pleased customer of this stuff.  Check out www.tapmagic.com and 
look specifically for 'Tap Magic for aluminum'.  This is "Good Stuff" and it 
is inexpensive.

Here in the States, Tap Magic is sold by McMaster-Carr, an industrial supply 
house that happens to be about a 20-minute drive from my house.  
McMaster-Carr can be found at www.mcmaster.com and they have their entire 
catalog on line.  (My printed catalog is a bit old but it is 3280 pages in 
length.)  Anyway, the McMaster stock number for Tap Magic (for aluminum only) 
is 1413K44 and costs $6.97 for a 16 oz. can.  It is listed on catalog page 
1974.  (The McMaster-Carr facility nearest my house has 32 truck docks.  Not 
exactly a garage-shop operation.)

Probably the most noticeable thing about this fluid is the lack of noise made 
by a drill bit as it bites into aluminum.  This stuff really quiets the 
drilling process.  I suggest using TiN coated (titanium nitride) drills and 
Tap Magic.  After several hundred holes, the drill bits look brand new.  TiN 
coated drill bits have be turned about 25% faster than uncoated varieties and 
they cost a bit more than standard steel or black oxide drills but I think 
they are worth it.

Cheers!
Tom Farrand (engage lurk mode)