I am a one-person company
I produce a raft frame in several sizes using 1 by 2 by 1/8 wall aluminum tubing for cross braces.
I have yet to find a way to cut burr free holes in this material. I typically need to cut several 1" diameter holes in the 2" wide face of each cross brace.
I currently use a 1" diameter drill bit in my drill press - and then have to spend a great deal of time removing the burrs afterward.
I was hoping someone here would know of a better solution.
BTW Back in the sixties I worked for a company in California who had the greatest boring tool for sheet metal - called a Rotobor, I believe. I haven't been able to find these anywhere so I assume they've gone out of business. So I know there is a way to do it - I just can't find it.
Thanks for any advice.