[JamesCH95]

Originally Posted by Cem8301

This is a good idea. We ran into a lot of weird design and logistics problems when making this design. For instance... I drove all around the Dallas metroplex looking for a 7/8 drill bit and brackets... And then as it turns out the drill bit I found was had the wrong shaft shape and it kept stalling in the drill press...

Thanks for the idea. I'll type it up this week.

Unless you're doing something crazy, step drills (aka unibits) like this are awesome for large-bore holes in thin material. They are available in many variants to fit whatever you want to do. Most hardware stores have them too. They frequently have a hex shaft, so no slipping in the chuck, and cut a small amount of material at a time, so no stalling and a very low chance of catching a part and spinning it. Plus they can be used to chamfer the hole when you're done.

Just a thought...