[trains are bad]

I have a thin, aluminum project box. I need to drill holes of all sizes, from 1/4, 5/8, 3/4 inches, because all my switches and jacks are different sizes. So if I buy all these as regular twist drills, it's going to cost a fortune. Plus, using twist drills with sheet metal doesn't always leave clean holes unless yous spin the drill really fast, and use a drill press.

Home depot has a step drill, that has all sizes from 1/4 to 3/4 inches. I'm pretty sure this exactly the right thing for drilling sheet metal. The only thing is it's $35.

What do you do to drill sheet metal?

 

[fordgtlover]

Pilot hole and a step drill. You view about the result is the same as my experience. The step bit gives a much better result IMO.

 

[Pars]

You could try these:

Harbor Freight Tools - Quality Tools at the Lowest Prices

I will warn you that these do not work as well as name brand unibits such as Irwin (on thicker stuff they chatter... damn near ruined a project for me). For thin stuff they work fine.

I also bought some Irwin unibits off eBay, so another option if you can wait.

 

[tomb]

Quote:

Originally Posted by Pars /img/forum/go_quote.gif You could try these: Harbor Freight Tools - Quality Tools at the Lowest Prices I will warn you that these do not work as well as name brand unibits such as Irwin (on thicker stuff they chatter... damn near ruined a project for me). For thin stuff they work fine. I also bought some Irwin unibits off eBay, so another option if you can wait.

The one on the far right (the one with the smallest graduations) of the Harbor Freight set does fine, although it will dull fairly quickly. The other two - as you say - are pretty much worthless. Still, it's a good buy just to get that one for ~$10.

The shoplifting is incredible in my local HF. They put these in a bin - maybe a hundred or so. In a few days, you can count on one hand how many still have that one bit left in the package. That and tap handles walk regularly out the door. I'm sure other stuff does that, too, but those are the ones I watch all the time.

 

[AndrewB]

The Irwin brand Unibits are worth the few extra dollars at Home Depot or Lowe's. I picked up a 2 piece set a few years ago and they 're still cutting well in aluminum and light steel.

 

[AndrewB]

Just as a afterthought; invest in a center punch as well ($5-$20). Either the manual type or a auto- spring loaded one. This way your drill bit won't walk off where you want to drill

 

[labmat]

I second the center punch; it's the only way to ensure your hole end up where you intended.

 

[Punnisher]

For the price I second the stepper bit suggestion. It's the cheapest option.

 

[malldian]

Harbor Freight Tools - Quality Tools at the Lowest Prices

Curious as well, too cheap?

 

[Pars]

Quote:

Originally Posted by malldian /img/forum/go_quote.gif Harbor Freight Tools - Quality Tools at the Lowest Prices Curious as well, too cheap?

Hmm, I might have to go pick one of those up. Stuff like that is usually OK at Harbor. Another good thing are the digital calipers

Harbor Freight Tools - Quality Tools at the Lowest Prices

6 or 8". They have specials on these quite often... seems I got my 6" for maybe $12-$13?

 

[tomb]

Quote:

Originally Posted by malldian /img/forum/go_quote.gif Harbor Freight Tools - Quality Tools at the Lowest Prices Curious as well, too cheap?

Not at all - those things are great. They'll pop little dents all day long. It's been recommended for building the MAX almost since day one: