Floating nutplates

[Dpearson]

For drilling aluminum I use low cost cobalt bits from Amazon, and treat them as consumable. I’ve been happy with this brand. IMG_0207.jpg
Yardstore has a great reference table for bit sizes, which I refer to daily. IMG_0208.jpg
I’ve used a #27 bit as a clearance hole for a #6 screw when installing nut plates. It’s a good match for the center peg of my nut plate jig, and resulting hole doesn’t seem to interfere with screw installation. I use the jig whenever I can, and resort to using a nut plate as a jig when there’s not enough room.

[500AGL]

Yes, #27 is perfect for a #6, and #40 for 3/32 rivets.

[SpruceForest]

The cobalt Drill America stuff on Amazon works fine and encourages sharp bits, plus you'll have them overnight on most sizes. Pan American has really nice bits as well as makes the Nova line of palm drills (what the Sioux line of palm drills used to be) with and without a keyless chuck (order Nova palm drill direct...the one time when the manufacturer is the least expensive source). I like the keyless chuck version, but keep a keyed chuck version set up for the primary and use the keyless for the musical bits stuff.

[jfoz]

Thank you for the confirmations! I'll be ordering more bits as they do seem to get dull quickly!