Quote:
Originally Posted by cdmiller
1. Use sharp new high-quality bits. Change often, they get dull fast.
2. Use high-rpm (air) drill for aluminum.
3. Use very light pressure on drill. Let the bit cut its way through the hole.
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Thank you everyone for the advice. I've contacted Vans with the pic and the copy of the plans showing exactly what hole it is.
Also, I've done some experiments based on all of your advice. The bit was definitely done. New bit is much much better. I can't believe I didn't realize that.
And I tried the technique using the #40 first and then the #30 and these holes are absolutely perfect. I will be doing that from now on.