How to Drill Aluminum Stock

Drilling aluminum stock bars requires precise measurement as well as control over the material. This is most easily attained by using a C-clamp and a drill press, rather than a handheld drill. Aluminum stock has a tendency to catch on the drill bit, particularly just as the bit is about to exit the bottom of the stock, making it difficult to prevent the metal from spinning on the drill bit, potentially causing injuries.

Drill press
Ruler
Pencil
Drill bit
C-clamp

Instructions

- 1
  Measure the aluminum bar stock with the ruler or other measuring device to determine the exact location of the hole. Mark the location with a pencil.
- 2
  Mount the aluminum stock to the work surface of the drill press, and align the drill bit over the mark where the hole is to be drilled. Make certain that the drill bit will extend as deeply into the aluminum as you require.
- 3
  Clamp the aluminum bar stock to the work surface using the C-clamp, and then tighten it securely in place. Double-check that the drill will touch down in the correct place, and then turn on the drill press.
- 4
  Lower the drill press slowly, particularly if the drill bit you are using is less than 3/16 of an inch in diameter. Even though aluminum is a soft metal, it can still break a small drill bit that is lowered too quickly. Continue drilling until you have reached the drilling depth that you desire. When complete, retract the drill bit and then turn off the drill press before attempting to remove the aluminum from the work surface.

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