Has any one any top tips on how to release summat in ally after I've stitch drilled it? When I've tried in the past I end up bending the piece or warping the edges.

Heavy hammer behind, cut with a sharp chisel & hammer.

Better yet, jig saw and file

What are you making, is it thin ally or thick ally.

Is it a case of one piece fitted in another so you can provide a gear type edge or just trying to cut a shape out of it?

Adrian

Have you tried using the drill side ways through the holes, works for me, but it does depend what the thikness is.

1.5mm ally for the dash.Two circles for the clocks. Didn't trust the hole cutter I have, tends to jump and wander

Push the drill you used left or right, it will easy do 1.5 mm.

Not sure of the hole sizes required, but what about one of the plasterboard or tile cutters such as item number 140165148746 on ebay. Perhaps with a slow drill it may do aluminium.

Basically just a trammel cutter.

Adrian

Chain drill 3.3mm holes (1/8", then drag the drill bit from one hole to the next in a clockwise direction with the material around half way up the flutes - it cuts better that way. Don't force it, let the bit do the work. Drill the holes as close together as possible.

Cheers fellas I'll give it a go. I like the chisel idea too. I've drilled them all close together. My right arms like popeyes now after keep using the drill!

I've used a pair of side cutters to snip between the holes in the past - worked for me in 3mm plate

I'd use the hole cutter with some tallow where the cut is, and the ally being cut clamped between two pieces of ply.

ATB

Simon

When chain dilling the idea is to start undersized so the holes don't meet then increase until they do... Then in theory the two parts will be separated once you have finished...

Dan

Just use a jig saw? You only need to drill
one hole to start from,

Cheers

Fred W B

I find a jigsaw really inaccurate and it tends to grip in the metal and doesn't like going round bends.

I've just made a dash from 2 mm ally. Drill one hole then use a nibbler.

Before I had the nibbler, I would do the hole drilling and increase drill size until a hack saw blade fits in them - saw the small inbetween bits by hand or else use a file.

If you can get the blade in try a woodworking coping saw, worked for me when I made my inlet manifold out of 12mm plate and my nose badge out of 3mm. Use with a bit of lubrication