Holes in copper sheet - senior moment

[Cushing H.]

folks - sorry about this. A while ago I posted a thread asking for secrets for drilling holes in thin copper sheet (~3/8") without the drill bit catching and winding up the copper. I left that thread to look up the info later .... and I will be darned if I can re-locate that thread right now when I need the info :-( .

I **think** the thread more or less ended up (from Stacy) with drilling a small pilot hole, then using a step drill to open it up to the final diameter .... but am not sure. so .... I have to ask the question again: what is the best way to produce a 3/8" hole in thin copper (for Wa handle separator construction) without deforming the sheet???

 

[Hubert S.]

folks - sorry about this. A while ago I posted a thread asking for secrets for drilling holes in thin copper sheet (~3/8") without the drill bit catching and winding up the copper. I left that thread to look up the info later .... and I will be darned if I can re-locate that thread right now when I need the info :-( .

I **think** the thread more or less ended up (from Stacy) with drilling a small pilot hole, then using a step drill to open it up to the final diameter .... but am not sure. so .... I have to ask the question again: what is the best way to produce a 3/8" hole in thin copper (for Wa handle separator construction) without deforming the sheet???

Here is a list of all the threads you started. I see one thread about a DIY step drill, is that the one you were looking for? There are a couple more about drilling, but I think they're about AEB-L.

 

[Cushing H.]

Hubert - I get an error when I try the link to all the threads I started (I also tried to find out how to do that .... but dont see it as an option on my search pane......)

 

[Natlek]

clamp it between two piece of aluminium or micarta

 

[WValtakis]

Hubert - I get an error when I try the link to all the threads I started (I also tried to find out how to do that .... but dont see it as an option on my search pane......)

Go to your profile page and click the "Postings" tab, then scroll to the bottom and click "Find all threads by Cushing H."

 

[Cushing H.]

thank you WValtkis. I just do not see the thread .... so I guess I am halucinating about the previous discussion??? So... I guess the question still stands. Natlek's idea would likely work (though would be somewhat wasteful of aluminum when drill many small spacer pieces). Any other ideas out there?

 

[Bill DeShivs]

Wood.

 

[WValtakis]

thank you WValtkis. I just do not see the thread .... so I guess I am halucinating about the previous discussion??? So... I guess the question still stands. Natlek's idea would likely work (though would be somewhat wasteful of aluminum when drill many small spacer pieces). Any other ideas out there?

Stack a bunch and drill them all at once (clamped between something sacrificial)?

 

[Natlek]

Natlek's idea would likely work (though would be somewhat wasteful of aluminum when drill many small spacer pieces). Any other ideas out there?

Stack a bunch and drill them all at once (clamped between something sacrificial)?

 

[A.McPherson]

How thin? If it's thin enough, you could make a punch and hole set.

 

[Richard338]

Wood.

I'm slowly coming to appreciate that Bill doesn't ramble on much, but usually knows what to do.
I agree with wood (same answer, more words).

 

[SS369]

I have used a Forstner bit on a hard backer, applying pressure close to the hole. Could do it between two pieces of MDF. It was only a 1/4 inch diameter though.
If it was only to perforate, I would mostly just use a nail on a hard board and sand it afterward.
Scott

 

[Hubert S.]

Hubert - I get an error when I try the link to all the threads I started (I also tried to find out how to do that .... but dont see it as an option on my search pane......)

Hmm, I guess that link only works for me. I got to the page like WValtakis explained and then linked that.

 

[Natlek]

many small spacer pieces). Any other ideas out there?

Why you need to drill hole if they are spacer for hidden tang ? I just use chisels for that ?
If they are for scale ......................just use new never sharpened drill bits to get perfect round holes

 

[J-T-K]

I have a pile of completely disposable pine offcuts and leftovers and they are great for clamping stuff

 

[Bill DeShivs]

I'm slowly coming to appreciate that Bill doesn't ramble on much, but usually knows what to do.
I agree with wood (same answer, more words).

No sense wasting words. You might need them later.

 

[Cushing H.]

Why you need to drill hole if they are spacer for hidden tang ? I just use chisels for that ?
If they are for scale ......................just use new never sharpened drill bits to get perfect round holes

Because I am assembling with a dowel (Wa handle)

 

[Cushing H.]

I have a pile of completely disposable pine offcuts and leftovers and they are great for clamping stuff

I’ll try the wood. I can get a really nice tight clamp with my mini mill.

 

[Cushing H.]

Update .... combining several ideas put forward here .... this is what I cobbled together this afternoon. two pieces of pine with alignment dowels, a pre-drilled 3/8" hole, and a sharpie-marked alignment mark showing where to place the edge of the copper so that the hole is more or less in the center of the 1.25" square of copper......


drilled cleanly.....

I'll take the results! And even better yet, I now have a jig for next time

 

[Natlek]

Good enough next time as last piece on bottom use some stainless spacer and they will come even better