Spehro Pefhany wrote in
:


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)?

Unless you have ton of them, I'd do 'em by hand with one of these:

http://www.brownells.com/.aspx/pid=6...RITE-TAP-GUIDE

Doug White