Paul Dye demonstrates the proper way to drill holes in aluminum sheet and bar. You’ll need sharp drill bits and a few easy to learn techniques to consistently make your holes round and in the right place. It pays to get good with drilling because you’ll be doing a lot of it.
Review a few more tips:
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Many people buying pneumatic drills do not know that they really need a “tease” throttle; it allows complete modulation of rpm at start. Another useful tip is to use extra flexible air hose and a lightweight swivel to remove much of the eccentric loading on the drill.
When I built my Xenos, I learned a lot about drilling metal. I would always use the drill press, if at all possible, for the most accurate holes. Lube too.
Don’t leave the key in the lathe chuck! Safety 101 in the metal shop.
Drill bits DO NOT drill round holes!