Epic fail drilling into aluminum

[fastpakr]

I’ve wandered through the listing info for the cases and identical ones under other brand names (they’re cheap generic cases). So far nothing I’ve found indicates it’s anything special, just ‘aluminum’.

 

[lil_Blue_Ford]

I’ve wandered through the listing info for the cases and identical ones under other brand names (they’re cheap generic cases). So far nothing I’ve found indicates it’s anything special, just ‘aluminum’.

I’ve wondered sometimes if some of the “aluminum” stuff we get that is made in other countries is more a sort of “pot metal” rather than graded aluminum because I’ve come across some that are really soft and some that are really hard.

 

[fastpakr]

I’ve wondered sometimes if some of the “aluminum” stuff we get that is made in other countries is more a sort of “pot metal” rather than graded aluminum because I’ve come across some that are really soft and some that are really hard.

It will be interesting to see if the side cases present the same issues. Those were ordered later under a different brand name. I haven’t tried to drill those yet.

 

[pjtoledo]

scratch test in a hidden location. if you can scratch it it's drillable.

 

[fastpakr]

Left bit is the one I tried to drill with last night for several minutes. Brand new prior, and the one on the right is brand new for comparison.

Second picture shows where I tried using my die grinder. It definitely chewed away some material but I’ll need to be more intentional about preparing to avoid scratches when it slips. Before and after doing that, I tried one of the new cobalt bits that came in the mail today. Still nothing… just blissfully spinning over the surface of the metal.

 

[85_Ranger4x4]

View attachment 145985View attachment 145986

Left bit is the one I tried to drill with last night for several minutes. Brand new prior, and the one on the right is brand new for comparison.

Second picture shows where I tried using a bit in my die grinder. It definitely chewed away some material but I’ll need to be more intentional about preparing to avoid scratches when it slips. Before and after doing that, I tried one of the new cobalt bits that came in the mail today. Still nothing… just blissfully spinning over the surface of the metal.

Any chance of a better picture of the end of the drill bits? Like the part that actually does the cutting.

 

[fastpakr]

Any chance of a better picture of the end of the drill bits? Like the part that actually does the cutting.

I’ll try - struggling to get the phone to focus properly.

 

[85_Ranger4x4]

I’ll try - struggling to get the phone to focus properly.

Getting a phone to focus should be as easy as drilling in aluminum,,,

 

[fastpakr]

Black zip tie on the one I used, next to an unused bit.

 

[Curious Hound]

Did you say these are 1/8" bits? They shouldn't normally need a pilot hole. But, have you tried 1/16"?

 

[fastpakr]

Those are 1/8, but yes - I’ve also tried 1/16.

 

[fastpakr]

Progress…

If I’m willing to embrace the reckless approach, I can just open the initial hole directly with the die grinder and then hand straight off to the step bit. Just managed three more holes in about ten minutes that way.

 

[85_Ranger4x4]

You got something weird there.

When I was trying to hog out a rib inside my aluminum GT-500 diff cover to fit the tone ring in my Explorer axle... die grinder plugged immediately with aluminum.

I wonder if it is some sort of nitride/anodizing or something.