On Mar 14, 12:42*pm, 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)?

While I could be wrong on this, given the fairly thin material, I
suspect you might get away with it.