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Tool Talk Discussion Forum

Drilling Holes in Finished Aluminum

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Twincreek

01-10-2008 10:01:17




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Hi - I am seeking ideas on drilling holes in finished aluminum. I need to drill a bunch of 7/16" to 7/8" holes in .040 finished aluminum. The holes must look nice with no rough edges or distortion of the aluminum. Does anyone have any ideas on what to use or what drilling procedure to use? Any input would be greatly appreciated.




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NTP

01-11-2008 16:14:45




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
There are special drill bits made for doing just what you are doing. I have a set of them, but can't remember what the correct termonolgy is for them. They look like a regular drill bit, but they have a blunt end and are sharpened differently. They will cut a very clean and burr free hole in thin sheet metal. I rarely use them, but they sure work well when needed.



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Twincreek

01-11-2008 13:00:08




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 Re: Drilling Holes in Finished Aluminum - Thanks in reply to Twincreek, 01-10-2008 10:01:17  
Thank you everyone for your responses!



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guido

01-11-2008 08:40:46




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
Hey Twincreek.
The is a reamer drill that would do a good job for you. I just looked at the ones I have, some have just a W on it made in U.S.A. The others are made in Brazil for skf.
Hope it helps.....Guido.



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Areo

01-11-2008 08:19:53




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
What works well for me is to clamp it between two pieces of wood. Hardwood preferred. This will stop distortion and minimize the burrs.

HTH
Areo



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Bud in WV

01-11-2008 04:02:51




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
If you don't have access to a punch, one of these is about the only thing that might not totally trash the work by "grabbing" -

Link

An "automatic center punch" would help, too. Here's a link to cheap one. It might work on aluminum, though.

http://www.jcwhitney.com/webapp/wcs/stores/servlet/Product?storeId=10101&Pr=p_Product.CATENTRY_ID%3A2007998&TID=8014524F&productId=2007998&catalogId=10101

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Vern-MI

01-11-2008 02:16:34




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
If you are using a drill press and have the material located to prevent creep then try a straight end mill and some cutting oil. Try this on a piece of scrap to get the feed just right. The straight flute will not make the material crawl up the bit as it breaks through.



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T_Bone

01-10-2008 16:46:29




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
Hi TC,

That's to thinn of material to drill that size of a accurate hole. It would be faster and cleaner to use a punch and die used for metal working machines. AL uses a closer tolerance die for clean holes than what steel requires so ask the saleman for dies for thinn AL.

You can make your own press really easy. Just use a compound jointed 18" long handle fir leverage to push the punch thru. Just go to any of the metal suppliers for the punch and die and scope out the punch press designs while your there.

T_Bone

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guido

01-10-2008 15:58:27




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
Hey Twincreek
There is such a thing as a reamer bit/drill.It looks like a reamer but it is a bit that flutes out to the size you need. We used them at work to drill aluminum frames, and they last a long tine.
I have some of my nown but i don't know the brand they are. I will look for you in the morning. You keep them wet while drilling and they do an exellent job.
Guido.



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Charles (in GA)

01-10-2008 13:00:53




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
Unibit is the cats meow for making clean holes in aluminum sheet.

Charles



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x22

01-10-2008 11:59:15




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
Your aluminum is so thin, I would use a Greenlee punch and die.



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CENTAUR

01-10-2008 10:57:31




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
The unibit is a very good suggestion by (CWL).Another way would be to use the (BLAIR)hole saws In an under size and finish with a unibit or Reamer.The Blair has a spring loaded Arbor witch would make very accurate holes if that be a must.Put BLAIREQUIPMENT.COM/ for inf on this product.All the tool trucks should have these available and many warehouses also.The unibit will be the lowest cost and will make smooth holes also. CENTAUR

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Twincreek

01-10-2008 11:11:37




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 Re: Drilling Holes in Finished Aluminum in reply to CENTAUR, 01-10-2008 10:57:31  
Do you back up the aluminum with wood if you are using the unibit?



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Gerald J.

01-10-2008 11:32:20




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 11:11:37  
Since the unibit is long, you can only back the aluminum up with wood that has a hole to pass the unibit.

Gerald J.



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Gerald J.

01-10-2008 10:39:50




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
Back up with wood. Drill with bradpoint wood drill bit.

Or punch with a hand punch. Like a Whitney or Greenlee. Mouser and Harbor Freight carry less expensive punches than Greenlees.

Gerald J.



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Kent in KC

01-10-2008 10:35:09




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
Put masking tape over it first, keeps the shavings from scratching up the surface as it spins around.



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CWL

01-10-2008 10:31:16




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 Re: Drilling Holes in Finished Aluminum in reply to Twincreek, 01-10-2008 10:01:17  
Try using a Unibit. It is a multiple step drill bit that electrical contractors use for drilling holes in thin metal for conduit connections.



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Bus Driver

01-10-2008 12:59:25




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 Re: Drilling Holes in Finished Aluminum in reply to CWL, 01-10-2008 10:31:16  
The Unibit is my choice also.



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BigMarv1085 fromGeorgia

01-10-2008 13:30:33




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 Re: Drilling Holes in Finished Aluminum in reply to Bus Driver, 01-10-2008 12:59:25  
I'm with Charles, use a unibit and put scotch tape over any smaller holes to prevent scratching the outer surface. Use a deburring tool to remove the sharp chips on the edge of the holes.



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