On Wed, 14 Mar 2012 15:42:31 -0400, Spehro Pefhany wrote:

Looking at using some relatively small screws tapped into (probably)
6061 aluminum. Through holes, maybe 0.08" of material. Is it insanity to
think about using a cordless hand drill and run them right through
without backing off (assuming a good quality coated tap and aluminum
cutting fluid)?

You're giving me stomach cramps just thinking about it.

Unless, of course, your goal is broken taps -- in that case, go ahead and
have fun!

--
Tim Wescott
Control system and signal processing consulting
www.wescottdesign.com