Metal Magic: Drilling Like a Pro


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:

This series is sponsored by Aircraft Spruce & Specialty.

View the complete list of published Metal Magic videos.


  1. 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.

  2. 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.


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