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  1. 25-09-2012 #1
    WandrinAndy's Avatar
    Lives in Yorks, United Kingdom.
    WandrinAndy
    Last Activity: 01-11-2013 Has been a member for 9-10 years. Has a total post count of 255. Received thanks 10 times, giving thanks to others 43 times. Referred 2 members to the community.
    I need to drill 4 x 28mm holes through aluminium to make ballscrew nut mounts.... from 1-3/4" 44mm square bar.

    Does anybody have any tips for doing this?

    I'm thinking of using a good quality bi-metal holesaw.... Irwin/Bosch... at 545 rpm in the bench drill press... Drilling a 6mm pilot hole first... and possibly drilling two 6mm holes at opposing ends of the diameter to help with clearing chips.

    Sure I would have to tackle the bar from both sides, but have no idea whether I would be fighting a losing battle, or whether cutting fluid would help keep the tool cool or have the opposite effect by making the chips gum up?
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