Quote:
Originally Posted by roystur44
best bit to use is a step drill
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I'll agree with what I see above except this. A step bit is like a crescent wrench - one tool does a lot of different stuff, but doesn't do any of it as well as the right tool does. Using a step bit requires grinding up every bit of aluminum in the hole, increasing time, energy, and waste. If you are going to drill more than a few holes of a given size, get an appropriate hole saw. Faster, neater, less swarf, and most of the aluminum you remove can be tossed in the recycle bin in one piece. I have also noticed step bit holes tend to "wander" off the intended location farther than hole saw holes, especially if drilled in a hurry.