wirejock
Well Known Member
I'm sure this isn't the proper way but maybe it will help someone a little.
Don't assume you're perfect measurements and punch marks will result in aligned holes when drilling stainless. Stainless is hard. You can measure, mark and punch all you want. Holes still wander a tiny bit as you enlarge them to final dimension bcause the bit tends to cut away material in an irregular pattern. The error is nore pronounced, the bigger the bit and hole.
Use the part to check every hole before drilling the next. Drill the first hole. Enlarge in small steps. Stick a bolt in. Mark and drill the next, repeat. It takes forever, but insures the bolts will fit where they belong.
Use Vans preexisting rivet holes whenever possible. It's one less hole to drill.
Buy small bits for pilot holes. Best you can find. Buy several. 1/16"-5/64" seem to work best. Strong enough to apply pressure without snapping and small enough to cut a tiny hole without wandering. Drill super slow and apply firm pressure as the bit and drill will allow. Go slow enough to count the turns. Use a really good cutting oil. I use Kroil in a spray can. The bit will cut and break through much quicker with tiny bits, before the stainless work hardens and drilling becomes almost impossible. Once you have a tiny hole, enlarging is easy in tiny steps. Don't be tempted to go for the final size. The bit will grab, cut off center and distort the metal. Go up no more than 10 at a step.
Example. A #12 hole starts at 5/64", ~#40, ~#30, ~#20, ~#14 then #12 reamer. Yes, takes a long time.
Good luck deburring. Lots of turns to remove the burrs. A Carbide burr in the Dremel works well for big holes.
Big holes are not so bad. Follow the same steps and ream the hole to 1/4". A sharp Unibit works pretty well up to 1". Same technique. Super slow with lots of cutting oil. If you see smoke, stop and add more oil. Hole saws work fine for 1" or larger with a polished steel pilot rod. Oil the pilot and the hole saw. Super slow. It actually cuts pretty quick. Spray with cutting oil often.
Don't go so fast you let the smoke out!
Don't assume you're perfect measurements and punch marks will result in aligned holes when drilling stainless. Stainless is hard. You can measure, mark and punch all you want. Holes still wander a tiny bit as you enlarge them to final dimension bcause the bit tends to cut away material in an irregular pattern. The error is nore pronounced, the bigger the bit and hole.
Use the part to check every hole before drilling the next. Drill the first hole. Enlarge in small steps. Stick a bolt in. Mark and drill the next, repeat. It takes forever, but insures the bolts will fit where they belong.
Use Vans preexisting rivet holes whenever possible. It's one less hole to drill.
Buy small bits for pilot holes. Best you can find. Buy several. 1/16"-5/64" seem to work best. Strong enough to apply pressure without snapping and small enough to cut a tiny hole without wandering. Drill super slow and apply firm pressure as the bit and drill will allow. Go slow enough to count the turns. Use a really good cutting oil. I use Kroil in a spray can. The bit will cut and break through much quicker with tiny bits, before the stainless work hardens and drilling becomes almost impossible. Once you have a tiny hole, enlarging is easy in tiny steps. Don't be tempted to go for the final size. The bit will grab, cut off center and distort the metal. Go up no more than 10 at a step.
Example. A #12 hole starts at 5/64", ~#40, ~#30, ~#20, ~#14 then #12 reamer. Yes, takes a long time.
Good luck deburring. Lots of turns to remove the burrs. A Carbide burr in the Dremel works well for big holes.
Big holes are not so bad. Follow the same steps and ream the hole to 1/4". A sharp Unibit works pretty well up to 1". Same technique. Super slow with lots of cutting oil. If you see smoke, stop and add more oil. Hole saws work fine for 1" or larger with a polished steel pilot rod. Oil the pilot and the hole saw. Super slow. It actually cuts pretty quick. Spray with cutting oil often.
Don't go so fast you let the smoke out!