As anyone who has ever had to pleasure of working on a motorbike or bicycle will tell you, you'll eventually have to drill holes in the thing for some reason. Usually it's for repair work, such as when there's a broken bolt that needs to be replaced.
There's a right way and a wrong one to go about this task. The wrong one will leave you with broken tools and possibly, injuries, while the right way leaves you feeling like a competent handyman, or person, as the case may be.
The absolute first thing you need is a sharp drill bit. You can refer to a drill and tap chart for the right one you need. These are based on the size of the hole you want to drill. Most of the time, this kind of job requires the use of the smaller drill bits. These drill bits are quite affordable, which is a blessing if you're the careless type who tends to break things. You can tell if your drill bit is sharp enough by testing it out first. If you have difficulty drilling a hole, then of course you should get a new one.
Cutting fluid is an essential component for this sort of drilling. There are a variety of brands at the store, so the choice is up to you. What's important is to choose the correct type of cutting fluid for the type of metal you have. This is because some cutting fluids are purpose-formulated for specific metal types. Using the right cutting fluid prevents damage to the drill, the metal and to you.
Now, you're ready to drill that new hole. First, you'll need to mark the spot where the hole is going to be. A centre punch and hammer can be used for this purpose. This is an important preparatory step to keep the drill in place. Otherwise, you run the risk of having the drill 'walk' all over the surface of your metal. On the other hand, if the center punch fails to make a discernible mark, it's likely that the metal you intend to work on is too hard to be drilled. You shouldn't use the largest measurement on the drill and tap chart in the hopes of overcoming this either. Forcing the issue is more than likely to result in a broken drill bit, which will cost more to remove than a mere broken bolt.
Once you've successfully drilled your hole, the taps can be used. Cutting fluid should be periodically added to aid the thread cutting. This is because taps are usually made of hardened steel, to ensure they have a long-lasting cutting edge. However, hardened steel can also be relatively brittle. Cutting a thread to the desired width usually begins with a starting tap, which is a tool that sharply tapers at the end. This is followed by a second plug tap that is less tapered and completed with a bottoming tap to finish out the thread.
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