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Re: drilling larger holes in aluminum
Layout all your holes first, and use a center-punch to guide the drill.
For drilling through 6061 Rectangular sections, I would also recommend a hole saw. The OD of the hole saw will keep it centered in the first hole, so it can cleanly go though and makes a parallel cut in the back side. A slower cutting speed, and liberal use of cutting fluid is the best method.
Cleanup with a deburring tool
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