Paul & Sabrina's Cheap EV Conversion

[ttoyoda]

They are very difficult to drill.

Did you notice anything printed on the side of that bar before you cut it up?
like 2024-T6 or 6061-T6 or 7075? IF the drill chips are long and stringy (they wrap into the flutes of the drill bit), it is because you have a soft grade of Al.

Put rubbing alcohol (isopropyl alcohol) in a squeeze bottle, put some in the hole regularly. For a 3/8 hole, try a drill rpm of about 750. Take the drill bit out of the hole every 3 seconds or so to clear the waste and add more alcohol. With the waste cleared and the hole lubricated it should go pretty fast, you can use a feed rate that is fast enough to produce a continuous drill chip.

There should also be a distinctive but faint noise from the drill bit when everything is set up right and the bit is cutting well, like a hiss or a sizzle.

[metroschultz]

I love this thread
I've been laughing so hard my dog is trying to call 911
Please don't ever lose your sense of humor
Schultz

[MPaulHolmes]

Originally Posted by dremd

Note to all EcoModders

If you need Air cooled VW Advice/ Instructions/ Information Chances are I have it.

So, what is that thing strapped to the body of the car inside the wheel well, above the right back tire? Is it important? I hope not... It doesn't have anything to do with the brakes does it?

Also, my brakes have no pressure. I push on them, and no braking happens. Is that really hard to fix? The e-brake works, so maybe I'll just use that for in-town driving. ya!

[MPaulHolmes]

Originally Posted by metroschultz

I love this thread
I've been laughing so hard my dog is trying to call 911
Please don't ever lose your sense of humor
Schultz

[MPaulHolmes]

Originally Posted by ttoyoda

Did you notice anything printed on the side of that bar before you cut it up?
like 2024-T6 or 6061-T6 or 7075? IF the drill chips are long and stringy (they wrap into the flutes of the drill bit), it is because you have a soft grade of Al.

Oh my gosh! I'm going out right after church to buy some rubbing alcohol. That sounds wrong! hehe.

Very good advice! I'm so excited to get those 12 things done (actually 9 things now)

Ya, it said 6061 aluminum. It was making that really cool stringy stuff around the bit. It is awesome. I let one of our foster children play with some, and they cut their finger. That's how I discovered how those things are really sharp. But also really cool too.

[ttoyoda]

Ya, it said 6061 aluminum. It was making that really cool stringy stuff around the bit.

If there was no T number after the 6061 then it is probably T0 which is the softest (or no) heat treatment. Nice thing about rubbing alcohol instead of kerosene is that it evaporates and does not leave a greasy mess.

[MPaulHolmes]

The drilling worked beautifully when I followed the directions of the drilling pro, ttoyoda. The rubbing alcohol worked perfectly! Oh, I'm so happy... Now, I'm painting each thing red, and using a thing that files them down so I know when everything is flat. I've done 2 so far (partially). I have to work at Sylvan tomorrow, but the day is soon approaching when I can completely assemble the coupler/adapter. Oh, I'm so happy...

[metroschultz]

Just curious,
Do you do all your work in the kitchen?
Or maybe more direct,
Why does it seem there is always food in your pics?
Are you a closet French Chef trapped in an Ecomodder Body?
Or are you secretly storing canned food for Armegaddon?
Or am I too nosy? Wouldn't be the first time.
Schultz.

[MPaulHolmes]

We have one room that is usable for building stuff (living with mother in law). So, when I'm not outside, I'm typically in my kitchen/livingroom/bedroom/pantry/baby's room/(all of those are the same room)

And now for something completely different...




(can you name that movie?)

Am I not turtley enough for you? 26 kids go in the water, shark's in the water, 20 kids come out, the ice cream man, he got the rest...

[ttoyoda]

The rubbing alcohol worked perfectly!

Glad to hear it. Very clever of you to think of using that straw in the picture to put the alcohol in, I will do that the next time I can find straws but not the squeeze bottle. The alcohol works with steel too, especially with hole saws. With the hole saw, cut plugs out of kitchen sponge, fill the hole saw center with them. Soak sponge with alcohol. As you drill, the sponge squeezes out the alcohol and the hole saw cuts very well.

If you get tired of holding stuff you drill with C clamps, you can splurge on something like this
http://www.harborfreight.com/cpi/cta...emnumber=31001

It goes on sale for 66% off now and then, or you can find it cheaper elsewhere.

Do not bother with this
http://www.harborfreight.com/cpi/cta...emnumber=94276
You might think you can use a drill press as a milling machine, but in practice the drill press quill will chatter and grab sideways loads. You might be able to cut balsa woold or styrofoam, but not metal.