"Spehro Pefhany" wrote in message
...


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)?
__________________________________________

Go for it! Removing broken taps won't be that bad. Try a drill guide to
keep them straight. Even wit broken taps it will be faster than any other
method.