You might try using an annular cutter, works something like a hole saw
but looks like a hollow end mill. You drill a pilot hole and then drill
out the slug of metal for the hole. Take a look at the kbc online cat
at page 63 at http://www.kbctools.com/usa/main.cfm I have a 1" R-8
shank one of these to use for tube notching, works great in alum. I
have even used it in solid without the pilot. A lot faster than step
drilling.

KMH wrote:
Greetings.

I have a question for this group. I operate a small auto accessory store.
One of my products, made from
6061 aluminum was being designed by a local company. Basically they were
drilling (maybe) a hole just shy of
1 inch wide all the way through a 2 X 2 X 2 piece of aluminum. I'm wondering
how someone would go
about accomplishing this? A drill press with a 1 inch bit, a mill with a
reamer? I'm lost. They shop is not wanting
to continue and I have to pick up where they left off. I do own a mini-mill
just for extra info. Please adivse if
I need to include more info.

TIA
Mike




--
James P Crombie
Slemon Park, PEI
Canada
Machinist - 3D Cad Design - Amateur Astronomer

http://www.jamescrombie.com