Hi everyone, ran into some trouble Sunday night while drilling the pilot holes for the wing strut attach fittings. Basically what happened was a combination of several stupid mistakes, not clamping the drill vice down well enough, using too short of a bit, not keeping the bit cool with lube, and attempting to continue on even though the aluminum was getting sticky due to a hot bit and the bit hanging up when pulling out due to the vice not being clamped down well enough. Anyway, after the other pilot holes were drilled in the other fittings, I came back to this one and attempted to drill the hole from the back side so I could use a punch to knock the broken bit out. I managed to get within about a half a bit or so (1/8" bit broken off) so I tried to knock the bit out with a punch, which broke in the process. I then used a 3/16" bit to open up both holes so I could use a bigger punch and get a better hit on the broken bit. After extracting the broken bit, I ran the 3/16" bit down the hole and then ran a 1/4" bit to open the hole up to finished size. The second shows the little "step" I was left with since the two holes were off just a bit...about 1/32 - 1/16" or so.
So...to those who have been here, can this part be salvaged to does it become the most expensive chuck of aluminum in my scrap bin to date? My gut is telling me one thing but my brain is telling me to exhaust all options before ordering another foot of bar. If I up size to the next bolt size I am scared that I will have edge distance issues and then their is the "looks" once it is complete. Being a crucial structural component, I would like it to be as close to perfection as realistically possible. Am I getting too crazy worrying about that little step or will it open up and allow the bolt to move starting a chain of events that we wouldn't like to experience?
Thanks in advance.
So...to those who have been here, can this part be salvaged to does it become the most expensive chuck of aluminum in my scrap bin to date? My gut is telling me one thing but my brain is telling me to exhaust all options before ordering another foot of bar. If I up size to the next bolt size I am scared that I will have edge distance issues and then their is the "looks" once it is complete. Being a crucial structural component, I would like it to be as close to perfection as realistically possible. Am I getting too crazy worrying about that little step or will it open up and allow the bolt to move starting a chain of events that we wouldn't like to experience?
Thanks in advance.
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