Hi all, first post and all that...

I have been successfully using a stepped drill to make lovely, perfectly formed holes in ABS, but I now have the task of moving on to aluminium sheet to do the same task.

What is also different this time around is that the aluminium comes in a flat plate form. The ABS was a box that I could clamp to the worktop and work on quite nicely using an electric hand drill.

So I'm considering buying a drill press from the likes of Machine Mart, as well as one of those hefty-looking clamps devices to hold the piece in place while I lower the step drill on to it.

But I don't understand how the clamping vice can hold a small sheet in place and allow a drill bit to pass thru the workpiece and not get fouled up the other side.

Can anyone offer any advice on this please?

Other sort of related question is this: can a router bit be used in a drill press? I mean from a practical point of view as well as safety. I have been routing out a rectangle of ABS in a jig of my own making, but I may well have to rout out another rectangle from another sheet of aluminium.

Thanks for any feedback and tips on the above, as well as any recommendation for a suitable press (very light industrial use).

I doubt the router cutter would do much in a drill press, probably a bit slow running, but would work on aluminium in a router. Slow the speed, and lubricate the cutter well.

As for the clamp, how big are the parts? Too big to fit in a machine vice, bigger than the drill table?

Normally you would position the part in the vice to allow the drill bit to pass through, on many smaller vices there is a gap in the middle.
Either that, or clamp it near the top of the jaws, with packing pieces at each end.

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Why isn't the number 11 pronounced onety one?

TY.

I might have to find a solution with the router, then, but that's no sweat.

The parts are about 50mm x 170 x 2mm.

Sounds like I could easily use the stepped drill bit, yes? Like I say, I only ever used it on ABS. I suppose aluminium will take its toll on the bit, even if only 2mm.

As for the routing, I need to rout a rectangle inside the piece, dimensions as described above.

Am I barking up the wrong tree thinking of getting a drill press? I think it will change my life!

Dont get one of the £50-£60 type ones, they are rubbish imo, far too much flex in them.

If the step drill is half decent, aluminium shouldn't be a problem for it. Get yourself some cutting oil. It will help it cut, and reduce any swarf sticking to the edges.

Out of interest, what size holes are you drilling? I may be able to suggest an alternative method, such as a Qmax cutter.
These will allow you to drill a pilot, which should be possible with just about any drill, then a punch and die are put either side, and a screw/bolt tightened to punch the hole. Quick process once you have done it a couple of times.

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Why isn't the number 11 pronounced onety one?