Have a 1" thick piece of Al that I need to drill a 3/4" diameter hole thru.
I have the normal home owner type of tools, but nothing for going thru
Have a electric drill of course, but only wooden drill bits up to the normal
3/8 inch dia size.
As this would be a one time deal, really don't want to buy anything
too expensive to do the job.
Any suggestions ?
I would take it to a local machine shop and have them do it. If you
have a good drill press with a 1/2" chuck and a new drill, you could
do it yourself if you could clamp the material so it wouldn't move.
That's a lot of material to go through.
Depends on what sort of hole you need- how precisely cylindrical,
perpendicular and located. (Which you don't specify.)
Hole--saw will hack a hole, with pretty rough sides. Use water-soluble
oil to cool both the material and the cutter. Aluminum melts readily,
and will clog the cutters. WD-40, being mainly kerosene, is probably
not what you want to use for coolant. Keep tool-speed down.
I would suggest taking it to a machine shop. They will make short work
of it and do a better job than you can. You will likely find they will
charge you less than the cost of the drill bit you will need to buy and may
well damage using.
While you may be able to do it yourself with your hand drill, as
aluminum is reasonable soft, that large a hoe in inch thick stock would not
If you don't need great tolerance or finish, a hole saw should do it,
and I'm wondering why no one yet suggested that you drill a 1/4" pilto
hole through the stock, use the hole saw to go half way through the one
inch thickness and then drill out the rest from the other side?
spend a couple bucks at the store and get a metal-drilling bit tfor
I think I spend about $4-5 (which is most cost efficient)on a bit, and
that bit lasts quite a few jobs like what you spoke.
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