Hi all. I am not a machinist by any means, but i have a (maybe) dumb question.
I have some 3/8" thick 6061 AL plate that i want to drill a 22mm hole through. Also, on the same center I'd like a 28mm hole halfway through, as the picture shows:
However, I only have limited tools - a handdrill, a drill press, etc...
Question: is it possible to do this with the tools i have, assuming i am will to spend a few bucks on bits or whatever? Would a combination of spade bits work? Also, it is not necessary to have it super accurate.
Thanks,
Byron
I have some 3/8" thick 6061 AL plate that i want to drill a 22mm hole through. Also, on the same center I'd like a 28mm hole halfway through, as the picture shows:
An externally hosted image should be here but it was not working when we last tested it.
However, I only have limited tools - a handdrill, a drill press, etc...
Question: is it possible to do this with the tools i have, assuming i am will to spend a few bucks on bits or whatever? Would a combination of spade bits work? Also, it is not necessary to have it super accurate.
Thanks,
Byron
For cutting Aluminium use methylated spirits as the lubricant. Failing that WD40 is okay.
I would recommend you use a drill press and buy (borrow) the correct metal bits. Better to have the correct tools and do a good job than try and do it for cheap and mess it up, plus, if you need the bits again for another job you will already have them. Bits are hardly expensive unless you want cobalt types or something.
Andrew
edit. MAKE SURE YOU SECURE THE ALUMINIUM BEFORE DRILLING, IF IT SPINS IT WILL CUT YOU BEFORE YOU REALIZE WHAT HAS HAPPENED AND WHEN I SAW CUT THATS IF YOU ARE LUCKY, IT WILL REMOVE AN APPENDAGE (FINGER) QUITE EASILY.
I would recommend you use a drill press and buy (borrow) the correct metal bits. Better to have the correct tools and do a good job than try and do it for cheap and mess it up, plus, if you need the bits again for another job you will already have them. Bits are hardly expensive unless you want cobalt types or something.
Andrew
edit. MAKE SURE YOU SECURE THE ALUMINIUM BEFORE DRILLING, IF IT SPINS IT WILL CUT YOU BEFORE YOU REALIZE WHAT HAS HAPPENED AND WHEN I SAW CUT THATS IF YOU ARE LUCKY, IT WILL REMOVE AN APPENDAGE (FINGER) QUITE EASILY.
Fostner bit will not work in aluminum.
You can open the hole with a step drill or hole saw: http://www.mkmorse.com/holes.html
The halfway notch can be done with a rabbeting bit (on a router mounted to a table) working your way gradually, 1/16th or so at a time: http://www.routerbits.com/cgi-routerbits/sr.cgi?1195583741_4141+25
You can open the hole with a step drill or hole saw: http://www.mkmorse.com/holes.html
The halfway notch can be done with a rabbeting bit (on a router mounted to a table) working your way gradually, 1/16th or so at a time: http://www.routerbits.com/cgi-routerbits/sr.cgi?1195583741_4141+25
Oh yes, step drills work great if you can get the right size. But if your material is thicker than the step it can be a pain to open the lower part straight out. I would use a drill press and clamp it on there, otherwise stop by a machine shop and they might do it for a couple bucks at the right place. Holesaw then router it, that could work too.
There is actually even simpler way to do the notch. Get one of those rotary files, mount it on a drill press, adjust the depth an manually cut out the halfway opening.
As to the main hole, a propel drill bit or hole saw would be the cheapest tools, step drills are rather expensive.
Wear leather gloves as you never know what can happen
As to the main hole, a propel drill bit or hole saw would be the cheapest tools, step drills are rather expensive.
Wear leather gloves as you never know what can happen
Attachments
From the side, the depth adjusted on a drill press table (after the main hole is drilled). By that I mean that file dia is smaller than the hole and you need to "carve" the opening by hand.
I used this method before and it worked fine, but you need a sharp tool.
http://www.discount-tools.com/rfilesindexmain1.htm
I used this method before and it worked fine, but you need a sharp tool.
http://www.discount-tools.com/rfilesindexmain1.htm
Cal Weldon said:I wonder what a milling shop would charge to do it.
Maybe a beer or two...
Seriously, a couple of bucks ... don't waste your time (and money).
Ok, you can predrill the hole 22mm, but halfway hole leave to milling shop. If you insist, than buy 28 mm milling tool and drill the halfway hole too...
Cheers,
ma_coule said:Maybe a beer or two...
Maybe in Slovenia
It is done free hand and it's better to use larger size file. Later the edge can be smoothed out with a sanding drum: http://www.woodcraft.com/search/search.aspx?query=sanding+drum&keyword=sanding_drum&refcode=06INMSNS
But if a suitable plate with exact size opening is available (preferrably from stainless steel) it could be attached to aluminum with double sided tape or glue and act as template too.
But if a suitable plate with exact size opening is available (preferrably from stainless steel) it could be attached to aluminum with double sided tape or glue and act as template too.
Of course specialized shop would be the easiest solution, I'm just trying to present alternative metal fabricating techniques, not neccessary useful to everybody.
Personally, I prefer to perform simple tasks like that myself, as finding friendly shop may be much more time consuming.
A knob sample cost me $200 at my milling shop.
Personally, I prefer to perform simple tasks like that myself, as finding friendly shop may be much more time consuming.
A knob sample cost me $200 at my milling shop.
As others have noted, you might need different techniques to make a pretty hole than an ugly one.
An ugly hole like this could be created with a hole saw. Drill the pilot hole, then halfway through with the smaller size saw bit, then all the way through with the bigger one. Because of the extreme kerf/set of the teeth, those things tend to leave a pretty rough surface.
If it were me, I'd drill it out a little undersize with a hole saw. Then, using a rabbeting bit in a router and a metal template (which you'll have to make) as a guide, enlarge the hole. A small sanding drum chucked into the drill press can be used to clean it up if need be.
This will be about as good as you can do in a small shop without any kind of milling capability. You can get it to the point where it's pretty clean, as for a recessed volume knob, for example, but it won't have thise nice parallel mill marks that you would get on a mill with a fly cutter. That kind of precision is pretty much impossible on a drill press unless you've got a custom-made cutting tool, and even then...
--Buckapound
An ugly hole like this could be created with a hole saw. Drill the pilot hole, then halfway through with the smaller size saw bit, then all the way through with the bigger one. Because of the extreme kerf/set of the teeth, those things tend to leave a pretty rough surface.
If it were me, I'd drill it out a little undersize with a hole saw. Then, using a rabbeting bit in a router and a metal template (which you'll have to make) as a guide, enlarge the hole. A small sanding drum chucked into the drill press can be used to clean it up if need be.
This will be about as good as you can do in a small shop without any kind of milling capability. You can get it to the point where it's pretty clean, as for a recessed volume knob, for example, but it won't have thise nice parallel mill marks that you would get on a mill with a fly cutter. That kind of precision is pretty much impossible on a drill press unless you've got a custom-made cutting tool, and even then...
--Buckapound
I did that opening with a hole saw. IIRC I used sanding drum to smooth it out a bit, but all in all it came out pretty nice anyway, considering existing anodizing: http://www.diyaudio.com/forums/showthread.php?postid=493493#post493493 The knob was done by hand too, on a drill press using disc grinder.
In a previous suggestion, I believe the large size saw bit should be used first (halfway through), then drill all the way through with smaller one.
In a previous suggestion, I believe the large size saw bit should be used first (halfway through), then drill all the way through with smaller one.
Attachments
- Status
- This old topic is closed. If you want to reopen this topic, contact a moderator using the "Report Post" button.
- Home
- General Interest
- Everything Else
- Drilling aluminum