Quote Originally Posted by Lee Roberts View Post
John could you not get this job done faster using a holesaw ? i'v never used Tufnol but i have been using holesaws to cut well holes lol in ali and its quite a quick way to do it ?
Ever tried a Forstner bit?

I was having a terrible time cutting a 40mm hole thru 30mm ally, contant clogging and getting very very hot despite coolant and the slowest speed on the pillar drill. Then this mad idea comes in my head "use the force Luke" sorry, "try a Forstner Jeff, try a Forstner" It cut like butter,and left a milled finish in the hole and this was a cheap £15 quid TiN coated set from Costco, Mastergrip I think. Being HSS they won't last as long as carbide but they are easy to sharpen.

Jeff. (we need a top tips forum)