Drilling (thin) Aluminium

[RantMachine]

Hiya all,

Got to drill a bunch of 10mm diameter holes in my new panniers in order to attach the fitting kit. They're made of 1.2mm thick aluminium. Haven't got a drill, so I'm looking at borrowing one from a friend and buying the relevant bit for it (he's only got bits for wood or masonry). Anyone able to advise what kind of bit should be used?

I realise this is probably a daft question, but I'm not a practical person in the slightest and I don't want to bugger it up and end up with wobbly panniers

[Stu]

If you don't want to bugger it up best get someone to do it

It depends on the size of the hole to be honest you might want to step the sizes but I can't see you needing to really

Go to machine mart or something and get some HSS drill bits

[RantMachine]

Under any other circumstances I'd run them over to Mackays and ask them to drill it for me for a few quid, but my shift hours mean I'm in work whenever they're open Somewhat tempted to ask a friend if they can take them there for me...

Having now run the oh-so-simple instructions through Google Translate, looks like I'll need a few other bits too, so a trip to B&Q is in order either way (thank you, late opening hours). "Easy to attach with basic household tools" my arse

Starting to get the feeling that I'll be lucky to have these attached in time for the rally... if the rack doesn't arrive until Thursday or Friday morning, it looks like it's luggage net time. Sods law, this is probably the only time I'll actually need them all year, apart from going food shopping

[Tango]

10mm holes Ollie? They're bl**dy big! What size bolts does it use to hold the panniers onto the frames?

[RantMachine]

It's 6.2 for the ones that hold it to the frame, the 10.2 is for the locking lever to go through.

[Fozzie]

Blast... If I wasn't so busy these next few weeks I'd have done it for a pack of cookies

Easiest way is get a centre punch and mark exactly where the hole is going to go, then use a 4mm drill bit or so (I would use), and make a pilot hole. Get the drill lined up, on the correct setting and build up the speed to a decent pace and apply pressure as the drill bit bites. Once it's through just fit the 10mm bit and line it up so it's sitting central, a quick check either side that it's not at an angle (an inbuilt spirit level on the drill is good here) and you're good to go.

[Tango]

Use bits of masking tape to put the marks where you are going to drill.....measure, measure and measure again before drilling.....

I'd put a block of wood behind where you are going to drill.....stops the ally distorting when you're putting pressure on it....and should stop the drill snatching as it goes through the ally.....

[RantMachine]

Thank you all for the advice, I succesfully didn't bugger it up

This was the 6mm holes, round two tomorrow - drilling 8mm holes then carefully enlarging them with a metal file. Thanks again to Bob for loan of the bits and file!