Drilling heads off countersunk Allen screws?

Chris Wilson · 2009-03-26T16:13:53+00:00

On race cars the floor trays are often carbon composite flat panels andheld to the main carbon tub by countersink Allen screws. Grounding orgeneral butchery sometimes makes the female hex unusable, or they arerounded off. Drilling is often the only way to remove them, by taking theirheads off and removing the rest with grips once the panel is out of theway. HOWEVER, I get through umpteen bits like this, good ones I might add.What am i doing wrong, a pistol drill is the only option. I start withmaybe a 1/8 bit then go to something like a 5/16 or 3/8 bit. I now have aretirement home for knackered drill bits..... Is there some trick to this?:)