I've been trying various things over the last few years and I'm just curious if there's any engineering geniuses out there that have a better way to do this...
I drill thousands of holes in 1" and 3/4" aluminum square tube (1/16" thickness). The holes are mostly around 1/4". The distances between the holes are varied... Could be anything from one inch to a foot. Also, the 1/4" holes have to go through both sides, but there is also a smaller third hole on one of the remaining sides that match each of the first two holes. Because I do so many of these, I'm just looking for the smartest and quickest method possible. Multi head drills are out because many of the holes are too close. CNC would be great, but that's not an option right now. What I have to work with is basically one drill press. So far I've just tried using one master piece and then altering the distance of an end stop. That's not great because then you have to move each piece in and out, which can get tiring since some pieces are 5' long. Then I went with a template, but the templates wear out fast and it also doesn't work well with the full size bits. A smaller pilot bit has to be used first for accuracy, so then that makes it even longer to drill everything twice. Another thing that slows things down is that even the smallest amount of burst burs on the bottom have to be removed in-between each drill move, or the burs will make the bottom uneven and destabilize the piece on the next hole.
So far I'm thinking that maybe I could have a jig where there's pre- marked holes along the length of a base tube, where you could move a peg tab from hole to hole, using that as your backstop. Then the burr problem could be eliminated by having the tube sit on top of the open end of a channel, so there would be space in the middle. I don't know, that's the best idea I've come up with, but it would still mean moving each piece in and out for one set of holes. Also, the more you shift things, the more you run the risk of screwing up. After drilling about
80 holes in one piece and then screwing one up because you flipped when you should have flopped... that's when you start looking for a gun. My dream is to have something where you just lock it in and watch it go, but I don't think I can get something like that right now.Dave