What kind of drill or bit do I need to drill die-cast aluminium?

I’m building an electronic device that I want to house in a Hammond Mfg 1590BB die-cast aluminium case. To achieve this, I need to drill holes in the case for the switches and knobs. Do I need a special drill or bit for this?

{ 7 comments }

Ontario Bodega August 21, 2010 at 2:13 pm

Use an HSS Metal drill bit, Black& Decker and Bosch are the best

robin August 21, 2010 at 2:36 pm

Any drill-bit will work as aluminum is soft and similar to hardwood. Squirt some water on the bit as you go because those aluminum shaving curls are hot! Cool your bit between holes.

PDOCAR August 21, 2010 at 3:22 pm

They have special drill bits for this but for a few holes a standard bit can be used. We used to use kerosene as a lubricant but if you don’t have kerosene a little wd-40 should work.

Good Luck!

Hondu August 21, 2010 at 3:49 pm

No, any drill bit will not work. Most any wood bit will bite too fast and soon be bound up or broken. Determine the size you need and ask at the hardware store for a metal cutting twist drill (standard, common metal drilling bit. Nothing special about it). Coolant/lubricant is an option, not necessary. PS. Black and Decker or Bosch do not manufacture drill bits. They buy them from companies such as National or American and add a bit of price to put their name on them.

It just struck me like lightning August 21, 2010 at 4:44 pm

reg twist drill(lowest grade-which normally is black steel) will do it. If it is sharp, it works just fine. Any drill, if dull, is a useless piece of *&^%( You don’t need water or drilling oil as it will cut through the metal so fast the bit has no time to get hot.

Just guessing August 21, 2010 at 5:09 pm

Use a drill bit meant for metal, drill slowly and lubricate the bit as you go with soapy water to cool it and keep it sharp.

Mark Klotz August 21, 2010 at 5:32 pm

aluminium is pretty soft so any bit for metal should work

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