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Old 04-16-2015, 09:40 PM
TinKnocker TinKnocker is offline
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Join Date: Jun 2014
Location: MD
Posts: 296

Gary is correct. You could also do the same thing with a 3/16 or 1/4" endmill. A half inch hole is a huge hole to drill in .063 aluminum. Typically if you try to go straight through with such a large diameter bit the tip of the bit clears through the sheet before the tips of the flutes and exerts a heavy lifting force on the metal, and a lot of times you'll end up with trianglish holes. Another option would be to cut smaller holes and then open them up after the fact with a drill press. If you go that route I would climb the bits up about a 16th at a time and clamp it well because a half inch drill puts a ton of torque on a part, and spinning sheet metal plays hell on the hands.

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