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Hole saws and aluminum

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looks like he was working with .063 the .090 with polycoat is nice stuff to work with. Once your done you peel off the poly coat and it looks beautiful.
 
Great site, I am watching other videos. Watch the one on prepping a drillbit for use with plexi. This is good stuff!
 
I'm going to give it a shot as soon as I find some free time. It looks like a great solution to an aggravating problem!

Thanks again, Dave. :thmbsp:
 
There are many very good craftsman videos on the EAA web site. If you attend the EAA Air-venture fly-in at the end of July there are many workshops dealing with this stuff along with one of aviation's best airshows.
http://www.airventure.org Being an aircraft builder / pilot I would find it hard to go without.
 
I tried this technique tonight, with good results. I'm sure it could have looked even nicer if I were a more patient human, but it got the job done. I don't think my cheap drill press has a low enough speed to do a really nice job.

Two holes down, and four (maybe six!) to go.

I'll post pictures later, as I don't want to divulge exactly what I'm working on just yet.
 
I don't trust that guy in the video. He still has all 10 fingers, which means he wouldn't even make a decent high school shop teacher.:D
 
Hey Dave, I uses to attend the fly-in every year for ten years. That was always a highlight of my year. I always flew the Cassutt I built.
 
Glad you all enjoyed the link. I just returned from this year's fly-in last night. 250,000 people but very well organized. djnagel, from your pictures it looks like a cassutt would have been a tight fit. (how did you tuck your beard in?) Jerry Couglin, from Baraboo has a cassutt in his hangar that is for sale. I'm 5'8" and find it very tight. Nice to know you fly though!
 
Hey Dave, I did the seatback mod which brings the seatback back 4" and my elbows fit into the wing root. It was snug not tight. However, when you do a loop or roll or inverted loop, it fit like a glove....and I liked that. Like I was wearing the plan.
 
KInda nifty vid there, but it occurs that if one sandwiched the alum between a piece of plywood on top (quick drill through) and a piece of 2x4 below the sheet (thicker lumber to keep the pilot steady and true, plus its something substantial under the alum, so theres no chance of stretching the panel while applying pressure), and clamp the hell out of them..that you could pull that off nicely with a cordless drill. the paraffin def helps. Other thing I wonder, if its thin enough, whether one could get away with running the drill backwards, so..wearing through the alum, and no grabbies from the teeth as they just break through, or..reverse just at the moment of truth for the final breathrough.
 
That's a very neat, simple method for holes. For material that thin, though, I would probably use a knockout set. Now for thicker material, that holesaw method looks like the ticket.
 
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