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Drilling 3/8" steel

rlanicek

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I'm building a welding table. Not nearly as nice as many I've seen here on Garage Journal, but it will work for me. The top is a piece of 3/8" steel I lucked into. I want to mount my vise on it but am concerned about drilling through the steel. The three holes would need to be about 1/2" (I haven't measured yet, but big).

Would I need a special bit? Should I start with a smaller starter hole and work up? Any tips?

Thanks!
 
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Jack Olsen

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Use a center punch to get a starting point. I did a 1/8" pilot hole on mine. I used a cheap low-RPM Harbor Freight drill and the coated Harbor Freight bits.

It's 1" thick plate.

BigDrill1265696956.jpg


Easy peasy.

HalfInchHole1265696968.jpg


A high speed drill will ruin your bits and make the job much more difficult.
 

Doug Arthurs

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The key to drilling is slow speed a good bit and make sure you are making a chip and not just grinding away. A little cutting fluid helps as well. Not motor oil or wd-40 actual drilling/tapping fluid.
 

sberry

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Yes, get an 1/8 bit, run the drill on hi and punch the holes, come back with a 1/4 on low on a battery drill and then 1/2 and put enough pressure on till it slows down about 1/4 or so.
 

Jswain

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Good advice, I'd also recommend starting with a pilot hole but be very careful with the pressure because the smaller bits break real easy once you get drilling thicker steel. Keep enough pressure on it that you are constantly seeing chips, and use some plain jane water in a spray bottle to keep the bits cool, spraying quite often…it will help clear the chips as well.
 

csp

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WD40 is not cutting oil, but it's better than nothing at all. I used it all the time when drilling. With a good bit and a slow drill speed, 3/8" is nothing.
 

Jswain

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You want to cool the bit not lubricate it. Try it out

EDIT: Sorry never seen you said cutting fluid, which I'm sure would do a fantastic job as well but water works wonders at keeping the bit nice and cool.
 

Jay W

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Cooling and lubricating are both good when drilling. If the table top is mild steel and you have a good quality HSS drill bit, 480 RPM is where you want to be.
 

JCByrd24

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1/8" pilot directly to 1/2". Stepping up in size is not recommend and not necessary (plenty of info if you want to google it). The 1/8" pilot will greatly reduce the amount of pressure you will need to get the 1/2" bit to actually cut, which is critical with a hand drill. It does this because the chisel point doesn't have to cut.
 

dr_clyde

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As been said, drill an 1/8" pilot hole from a punch mark. Get a 1/2" drill or whatever size you need and use 4-500 RPM with pressure and use cutting fluid. You can get a small bottle for a couple bucks. Shouldn't take much effort. Concentrate on drilling straight and square, and keep steady enough pressure that it pulls a good chip.
 

racingtadpole

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Maybe you guys do things differently in the northern hemisphere but I was always told that to drill a hole that big its best to do it in stages. I'd pilot with an 1/8" and drill it an 1/8" at a time until I had the 1/2" but it looks like Im in the minority on that one.

Speed of rotation and feed are important as everyone else has already mentioned.
 
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toolman1967

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We just did this exact job on our work table. Small pilot bit then the finish size with lots of coolant and lubricant while using a slow speed.

Tim the Toolman
 

A_Pmech

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To answer your questions:

A twist drill ground in the usual manner orbits the axis of rotation until both the dead center and margins of the drill are in contact with the workpiece. By drilling an over-sized pilot hole, half the stabilizing forces acting on the drill are lost.

The hole produced by an orbiting two-flue drill isn't actually an octagon, but a a series of superimposed reuleaux triangles. The relative angle of the superimposition is roughly equal to the helix angle of the drill.

Twist drills have relief angles in excess of what is required for feeding and substantial positive back rake of the cutting edge. Without opposition by the dead center of the drill, the cutting edges will "self feed." That's a great way to break your arm with the inertia stored in the drill motor armature. Small pilot holes reduce the self feeding tendency by providing some opposing resistance to the cutting forces.







If you go from 1/8" straight to 1/2" be prepared to break your wrists when the bit grabs (which it will if you use a hand held drill) and be prepared for a hole that has more of an octagon appearance than circular.

Maybe you guys do things differently in the northern hemisphere but I was always told that to drill a hole that big its best to do it in stages. I'd pilot with an 1/8" and drill it an 1/8" at a time until I had the 1/2" but it looks like Im in the minority on that one.

Speed of rotation and feed are important as everyone else has already mentioned.
 

kerrynzl

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I just did a few today 12.5mm into 10mm steel. [ 1/2" into 3/8"steel ]
Use Cutting oil

I did it with a slow speed [gear reduction] hand held drill and a 5/16 pilot hole.
It was easy

Make sure the drills are sharp.
 

theoldwizard1

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I did it with a slow speed [gear reduction] hand held drill and a 5/16 pilot hole.
It was easy

All of those "in the know" have said (basically) "go slow" !

This is why everyone should have 2 drills ! First a 3/8", probably battery operated one. Mine is a really cheap light weight Black&Decker.

Second should be a corded (IMHO) TRIPLE reduction 1/2" drill, with a maximum speed of 600-750 rpm. Not many out there, but boy do they have torque !
 

Mr.N

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Don't do it



Mount a piece of receiver tube below the table and mount the vice on to some 2" square steel. Then slip the vice int the receive tube, and easly remove if its in your way
 

Kevin54

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For doing something like that at home, 9 times out of 10, you have to do it different than in a factory with factory equipment. To pop a 1/2" hole in 3/8" steel, at work, I would centerdrill the hole with a 1/2" centerdrill, then go directly to using a 1/2" drill bit, or a 15/32" drill bit, then ream to 1/2".

For home, I would center punch the plate, use a 3/16" drill bit, then step up to a 1/2" or maybe add a drill bit in between the 3/16" and the 1/2".

Your 1/2", especially if using a hand drill, will go through quicker if you have a pilot hole. And your pilot hole will go relatively quick as the bit is smaller. And theres no reason that a standard HSS bit won't work. I've drilled hundreds of thousands of holes over my 32 years of working with metal, and 99% of the time, the holes were drilled with HSS bits.

The biggest thing to watch out for is when you start to break through the other side. If you are leaning on your drill and break through, the bit will screw itself through the last little bit of metal and possible sprain your wrist. It's hard to let go of the trigger when it whips around. A corded drill is worse. If you use a drill press, just make sure your part is clamped or braced against the column.
 

pmason0

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This is how I did mine, set the drill on the slowest rpm, using cutting oil. I then put the tap into the drill press to keep it vertical.
drilltable.jpg
 

theoldwizard1

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The biggest thing to watch out for is when you start to break through the other side. If you are leaning on your drill and break through, the bit will screw itself through the last little bit of metal and possible sprain your wrist. It's hard to let go of the trigger when it whips around. A corded drill is worse. If you use a drill press, just make sure your part is clamped or braced against the column.

Hell, my triple reduction 1/2" drill wants to BREAK your wrist. I also seem to forget to use the extra screw on handle for 2 hand operation when I do large holes.
 
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May Pop

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Thats the Milwaukee Hole Shooter (Wrist Breaker). I would never let my kids use them when they were little as I was afraid of them getting hurt. Seen a few guys at work get hurt using them. They no longer send them out.
 

Lambo nut

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Maybe you guys do things differently in the northern hemisphere but I was always told that to drill a hole that big its best to do it in stages. I'd pilot with an 1/8" and drill it an 1/8" at a time until I had the 1/2" but it looks like Im in the minority on that one.

Speed of rotation and feed are important as everyone else has already mentioned.

That and your drill bits turn the other way don't they?!;)

I have done 3/8" steel easy with a 1/8" then the size needed. Now if I an going to say a 3/4" hole I might pick something in between for a step. I use a little motor oil while drilling. Better then nothing I guess.

Kevin
 

R.Anderson

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This is how I did mine, set the drill on the slowest rpm, using cutting oil. I then put the tap into the drill press to keep it vertical.
drilltable.jpg

This look like it could of gone very wrong. Drill press on a crate barely wide enough with what looks like cheap plastic office casters. What brand is that drill press?
--------------------------

Pending on what type of drill bits you have, drilling a pilot hole may not be necessary. Don't bother drilling a pilot hole if your using split point or pilot point drill bits. Just center punch and drill. Like others said take it easy at the end of the hole if using a hand held pistol drill, its a wrist popper if done wrong/ gone wrong. If you have access to a mag drill consider using it.
 
OP
R

rlanicek

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Thanks for your help. It wasn't as bad as I imagined. Started with a 1/8" pilot hole then drilled a 1/2" hole. On each of the three holes the drill did catch and try to break my wrist but backing it out and going back in slowly did the trick. I used 3-in-1 oil to lubricate/cool and it seemed to work just fine.

Once I get the vise refinished I'll post pics on "The Vises of Garage Journal" thread.
 

bluebolt

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Try drilling 3/4" holes in 1" plate with a hand drill. Now that's fun LOL. Just got done with that a week ago to mount my Reed 206 monster vise.
 

amolaver

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To answer your questions:

A twist drill ground in the usual manner orbits the axis of rotation until both the dead center and margins of the drill are in contact with the workpiece. By drilling an over-sized pilot hole, half the stabilizing forces acting on the drill are lost.

The hole produced by an orbiting two-flue drill isn't actually an octagon, but a a series of superimposed reuleaux triangles. The relative angle of the superimposition is roughly equal to the helix angle of the drill.

Twist drills have relief angles in excess of what is required for feeding and substantial positive back rake of the cutting edge. Without opposition by the dead center of the drill, the cutting edges will "self feed." That's a great way to break your arm with the inertia stored in the drill motor armature. Small pilot holes reduce the self feeding tendency by providing some opposing resistance to the cutting forces.

i apologize for my ignorance, but trying to parse through the details i'm not sure i'm interpreting you correctly. am i correct that you are recommending a small pilot hole followed by drill-to-finished-size? if so, is there a way to determine the 'correct' pilot, or would 1/8 (or something) be a reasonable first step for anything up to say, 3/4 final size?

thank you for the technical detail - amazing the thought that has gone into the evolution of these 'simple' tools.

ahm
 

wbrian63

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How big the pilot needs to be depends on the final as-desired hole size.

Anything less than 1/4" I go straight through.

1/4" + to 1/2" I use something around 1/8" - typically picking a less-used bit out of the index as they tend to be sharpest :)

1/2" > 3/4" - I use a 1/4" (or 9/32 - sharper) pilot.

To determine how big the pilot needs to be, look at the end of the final-size bit. The chisel point that is described by the intersection of the two cutting edges is the part of the bit that doesn't cut (as well) as the cutting edges. Make the pilot slightly larger than the width of the chisel and you're good to go.

Trick with drilling any hole is to listen to the drill. The cutting sound will change as the bit starts to come out through the back of the hole. With small bits, there's very little warning, especially if you're pushing hard and the cutting is moving smoothly. With larger bits, you should be moving slowly anyway, and you should hear the change in sound and know to ease off on the drilling pressure.

When drilling thicker steel that won't fit in the drill press, I first drill the pilot size in a piece of thicker scrap (3/8" or better is best), on the drill press. I clamp the scrap in place over the hole to be drilled and use that pilot hole to make sure I keep the drill bit perpendicular to the face of the material.

If the pilot hole is straight, the next drill should follow nicely.

One other thing - I have this problem on my Delta POS drill press and others would be wise to watch for the same problem. When I bear down on the drill to cut, the table gives just a bit. I've checked all of the mounting points and it's just the cheap design of the unit that causes the problem.

Anyway - when the table "gives", that changes the angle of the hole with respect to the bit. If you don't "peck" at the drill (release the pressure and reapply), then the final hole will come out at an angle.

The big risk is that when the bit punches through the back side of the material, the table will jump back into its original location, which will make the hole now no longer perpendicular to the bit and the drill will grab the part and try to lift it from the table.

My solution until I can figure out what to do about this POS is to peck-peck-peck about every 1/8" or so as I cut through. This has the advantage of breaking off any curly-ques that might be coiling off the bit as well, plus it keeps the hole from getting too far off perpendicular.
 
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kazlx

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Vise looks good enough as it is. Drilling 3/8" isn't too bad, but a heck of a lot easier with a rigid setup and sharp bits. Looks like you got it figured out though. For mounting a vise, perfect holes aren't that terribly important :)
 

A_Pmech

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Amolaver,

In short, the best pilot drill is one that is smaller than the width of the dead center of the drill. The purpose of the pilot drill is solely to reduce the feed force of the drill that follows. It does this by clearing the metal from in front of a portion of the dead center of the following drill. This metal is not cut by the drill, but pushed out of the way. This forming action produces a lot of heat and substantially increases the feed force.

Yes. Step drilling is a waste of time and likely to damage the drill. The large stress gradient across the cutting edge of the drill when step drilling causes the drill to fracture and "beach". That is, portions of the cutting edge are broken away closest to the peak of the stress gradient.


i apologize for my ignorance, but trying to parse through the details i'm not sure i'm interpreting you correctly. am i correct that you are recommending a small pilot hole followed by drill-to-finished-size? if so, is there a way to determine the 'correct' pilot, or would 1/8 (or something) be a reasonable first step for anything up to say, 3/4 final size?

thank you for the technical detail - amazing the thought that has gone into the evolution of these 'simple' tools.

ahm
 

wbrian63

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Yep - I couldn't figure out why I was having so much trouble with bits wanting to grab and lift, or turning out an obviously off-angle hole. Then I finally noticed that the table was moving when I pushed down on the drill.

Never saw this when working with wood - go figure.

Press wasn't a cheap-o - about 6 years old, 17" model. Many of the parts for the adjustable table were cast and broke over time and are no longer available as replacements... sad.

Before I spend more $ on another DP, I'm going to investigate buying a knee mill instead.
 

sberry

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I don't use either, hand drill. I rarely need a perfect hole for anything. Could just as easily plasma cut most holes.
 
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