I have to make some 1-1/4x.120" wall cable stair railing posts. The stairs go up at about a 36 degree angle. The tubes have to be drilled at that angle. Well, either that or I have to drill both sides and carefully lay out the holes. I figure it's faster to drill at an angle. I'm going to do it on the Bridgeport, with the tube clamped in the mill vise and supported on both ends by machinist jacks. I'll slew the head around to the correct angle. This much I've done a bunch of times.
The holes will be 3/16" in diameter.
Here's the hard part. How can I drill the hole without having the drill walk around on me? Normally I use a screw length bit and it goes in correctly. But a3/16" stub length bit isn't long enough to reach the back side at an angle, and a jobber's length bit will walk around on the inside edge of the backside randomly, giving me hole location errors. Is there any solution to this?
I guess I'll have to drill one side, flip the part, reverse it end for end, and drill the other side. Carefully.
Is there any way around this?