Drilling holes in thin metal - UK Vintage Radio Repair and Restoration Discussion Forum

60 oldjohn · 3rd May 2022, 9:18 pm

How to drill accurate 11mm holes in 0.8mm metal with a standard HSS drill safely. How many others were aware of this trick? I was not!

https://www.youtube.com/watch?v=cAGiuXOKKi8

John.

wireman · 3rd May 2022, 10:27 pm

New one on me, if someone said it was a challenge to try this in one go I would have tried to sandwich the sheet between two bits of wood clamped down in more than one place but you would have to be careful to align it.

60 oldjohn · 3rd May 2022, 10:54 pm

Some model engineers here may have read the original article in the magazine. I wish I knew this 50 years since.

John.

cmjones01 · 3rd May 2022, 11:08 pm

That's amazing. I've always relied on clamping the sheet firmly and backing it with a piece of scrap wood, with mixed results, but I'll certainly be trying this trick in the future. Thank you for posting it.

Chris

joebog1 · 3rd May 2022, 11:13 pm

I was taught the trick 45 years ago by an old sheet metal worker that made chassis for me.
I never thought about it before.

Joe

emeritus · 4th May 2022, 12:14 am

What a great tip, thanks for posting it.

John10b · 4th May 2022, 9:00 am

Yes a great tip, thanks for passing this on.
John

kalee20 · 4th May 2022, 9:10 am

I've never come across this, but I'll definitely give it a go! Drilling 1/2" holes in sheet aluminium for a toggle switch will hopefully be much easier!

Thank you!

60 oldjohn · 4th May 2022, 9:28 am

Quote:

Originally Posted by kalee20

I've never come across this, but I'll definitely give it a go! Drilling 1/2" holes in sheet aluminium for a toggle switch will hopefully be much easier!

Thank you!

Please try it on a similar piece of scrap ali first, as it may depend on the type of cloth used. I only found the Youtube clip last night and not had chance to try it yet.

John.

Craig Sawyers · 4th May 2022, 10:03 am

My Dad was a time served apprentice at Vickers Armstrong, and was a superb precision engineer. And I am 100% certain that he did not know that particular trick.

Looking forward to giving it a bash

Craig

snowman_al · 4th May 2022, 10:36 am

OLdJohn
Many thanks for posting that!
It does actually work too.
How many times in the past I've sandwiched thin stock to drill it...
Alan

The Philpott · 4th May 2022, 11:31 am

We'll see how critical the provision of a pillar drill is...with a steady hand i think it would work without.
Dave

Andrew2 · 4th May 2022, 11:51 am

Wow, that's incredible! The number of times I've avoided thin sheet because of this exact issue! I've got a nice tin box that is aching for a project to be built into it, but every time I pick it up I think about the horror of making neat holes in it.

fetteler · 4th May 2022, 12:06 pm

Truly a top tip - thanks for posting.

Steve.

Reelman · 4th May 2022, 1:00 pm

Very useful, must give it a try. Many a time I’ve seen a biscuit tin or similar that would make a fine chassis but have always discarded it if it needed some holes! If this trick works with thin tin plate then it is a real winner.

Peter

Steve_Bell · 4th May 2022, 1:20 pm

I think I would still use something to hold the workpiece (not my fingers) or clamp it.

60 oldjohn · 4th May 2022, 1:39 pm

Quote:

Originally Posted by Steve_Bell

I think I would still use something to hold the workpiece (not my fingers) or clamp it.

I would agree with that.

John.

ex 2 Base · 4th May 2022, 2:25 pm

A good tip, never the less i suggest the thin plate should securely clamped down before thing gets wizzing round and out of control. I have Fobco bench drilling machine, and have fitted a foot operated mains switch, now both hands free to control things. In Model Engineer or its stable mate MEW, there was a very useful article on adapting a MOLE type wrench with a bit of welding for clamping sheet steel. Ted

newlite4 · 4th May 2022, 5:07 pm

I only wish that I had been shown this 45 years ago when I started my 5 year technicians apprenticeship, too late now that I am retired, damn!
Neil

duncanlowe · 4th May 2022, 9:39 pm

In EWTP (metalwork) at school the technique we were taught was a modified drill bit with a much shallower angle. Have never tried it, though.

3rd May 2022, 9:18 pm	#1
60 oldjohn Dekatron Join Date: Dec 2004 Location: East Yorkshire, UK. Posts: 3,987	Drilling holes in thin metal How to drill accurate 11mm holes in 0.8mm metal with a standard HSS drill safely. How many others were aware of this trick? I was not! https://www.youtube.com/watch?v=cAGiuXOKKi8 John. __________________ My favourite text message "I'll be there in five minutes, if not read again"

3rd May 2022, 10:27 pm	#2
wireman Heptode Join Date: Feb 2021 Location: Edinburgh, Scotland, UK. Posts: 528	Re: Drilling holes in thin metal New one on me, if someone said it was a challenge to try this in one go I would have tried to sandwich the sheet between two bits of wood clamped down in more than one place but you would have to be careful to align it.

3rd May 2022, 10:54 pm	#3
60 oldjohn Dekatron Join Date: Dec 2004 Location: East Yorkshire, UK. Posts: 3,987	Re: Drilling holes in thin metal Some model engineers here may have read the original article in the magazine. I wish I knew this 50 years since. John. __________________ My favourite text message "I'll be there in five minutes, if not read again"

3rd May 2022, 11:08 pm	#4
cmjones01 Nonode Join Date: Oct 2008 Location: Warsaw, Poland and Cambridge, UK Posts: 2,677	Re: Drilling holes in thin metal That's amazing. I've always relied on clamping the sheet firmly and backing it with a piece of scrap wood, with mixed results, but I'll certainly be trying this trick in the future. Thank you for posting it. Chris __________________ What's going on in the workshop? http://martin-jones.com/

3rd May 2022, 11:13 pm	#5
joebog1 Banned Join Date: Jun 2015 Location: Mareeba, North Queensland, Australia Posts: 2,704	Re: Drilling holes in thin metal I was taught the trick 45 years ago by an old sheet metal worker that made chassis for me. I never thought about it before. Joe

4th May 2022, 12:14 am	#6
emeritus Dekatron Join Date: Jan 2012 Location: Brentwood, Essex, UK. Posts: 5,339	Re: Drilling holes in thin metal What a great tip, thanks for posting it.

4th May 2022, 9:00 am	#7
John10b Nonode Join Date: Nov 2016 Location: Aberaeron, Ceredigion, Wales, UK. Posts: 2,884	Re: Drilling holes in thin metal Yes a great tip, thanks for passing this on. John

4th May 2022, 9:10 am	#8
kalee20 Dekatron Join Date: Feb 2007 Location: Lynton, N. Devon, UK. Posts: 7,081	Re: Drilling holes in thin metal I've never come across this, but I'll definitely give it a go! Drilling 1/2" holes in sheet aluminium for a toggle switch will hopefully be much easier! Thank you!

4th May 2022, 10:03 am	#10
Craig Sawyers Dekatron Join Date: Nov 2010 Location: Oxford, UK. Posts: 4,982	Re: Drilling holes in thin metal My Dad was a time served apprentice at Vickers Armstrong, and was a superb precision engineer. And I am 100% certain that he did not know that particular trick. Looking forward to giving it a bash Craig __________________ Doomed for a certain term to walk the night

4th May 2022, 10:36 am	#11
snowman_al Octode Join Date: Dec 2018 Location: Llandeilo, West Wales, UK. Posts: 1,092	Re: Drilling holes in thin metal OLdJohn Many thanks for posting that! It does actually work too. How many times in the past I've sandwiched thin stock to drill it... Alan __________________ Never Leave Well Enough Alone...

4th May 2022, 11:31 am	#12
The Philpott Dekatron Join Date: Aug 2016 Location: Colchester, Essex, UK. Posts: 4,106	Re: Drilling holes in thin metal We'll see how critical the provision of a pillar drill is...with a steady hand i think it would work without. Dave

4th May 2022, 11:51 am	#13
Andrew2 Nonode Join Date: Mar 2010 Location: Dukinfield, Cheshire, UK. Posts: 2,037	Re: Drilling holes in thin metal Wow, that's incredible! The number of times I've avoided thin sheet because of this exact issue! I've got a nice tin box that is aching for a project to be built into it, but every time I pick it up I think about the horror of making neat holes in it. __________________ Andy G1HBE.

4th May 2022, 12:06 pm	#14
fetteler Octode Join Date: Jul 2011 Location: Staffordshire Moorlands, UK. Posts: 1,475	Re: Drilling holes in thin metal Truly a top tip - thanks for posting. Steve. __________________ Those who lack imagination cannot imagine what is lacking...

4th May 2022, 1:00 pm	#15
Reelman Octode Join Date: Aug 2008 Location: Rotherham, South Yorkshire, UK. Posts: 1,723	Re: Drilling holes in thin metal Very useful, must give it a try. Many a time I’ve seen a biscuit tin or similar that would make a fine chassis but have always discarded it if it needed some holes! If this trick works with thin tin plate then it is a real winner. Peter

4th May 2022, 1:20 pm	#16
Steve_Bell Hexode Join Date: Sep 2004 Location: Newcastle upon Tyne, Tyne & Wear, UK. Posts: 474	Re: Drilling holes in thin metal I think I would still use something to hold the workpiece (not my fingers) or clamp it.

4th May 2022, 2:25 pm	#18
ex 2 Base Heptode Join Date: Nov 2009 Location: Scarborough, North Yorkshire, UK. Posts: 510	Re: Drilling holes in thin metal A good tip, never the less i suggest the thin plate should securely clamped down before thing gets wizzing round and out of control. I have Fobco bench drilling machine, and have fitted a foot operated mains switch, now both hands free to control things. In Model Engineer or its stable mate MEW, there was a very useful article on adapting a MOLE type wrench with a bit of welding for clamping sheet steel. Ted

4th May 2022, 5:07 pm	#19
newlite4 Octode Join Date: Nov 2003 Location: Bath, Somerset, UK. Posts: 1,805	Re: Drilling holes in thin metal I only wish that I had been shown this 45 years ago when I started my 5 year technicians apprenticeship, too late now that I am retired, damn! Neil __________________ preserving the recent past, for the distant future.

4th May 2022, 9:39 pm	#20
duncanlowe Nonode Join Date: Jan 2016 Location: Stafford, Staffs. UK. Posts: 2,532	Re: Drilling holes in thin metal In EWTP (metalwork) at school the technique we were taught was a modified drill bit with a much shallower angle. Have never tried it, though.