I'm preparing for my Hella driving light install, and realized today while talking to my guy that I'm going to need to drill a hole in the center of my lights' mounting clamp to match the installation holes in my brackets - I'm using the Mini Madness-type brackets on this project, which have single holes and clamps that came with TWO offset holes. If I had access to real metal-working tools, I'd simply recreate the bracket with a single hole and some slight differences - I know it would be child's play if I had the right equipment, as the bracket is dead-simple, but alas, that looks to be a project for another day...

So, assuming I keep the existing light clamps for the near future, I'll need to drill two 1/4" holes through what feels like steel, 1/16". Assuming I tap the center to try and create some tooth for the drill bit, am I just wasting my time thinking I can cut through that material with just a hand drill? I'll stop by the hardware store later this week and see about a new bit, but I haven't had to drill through metal since shop class, and I don't have access to a drill press. Any metal worker type guys out there that can provide pointers, before I put my eye out with a flying, broken bit? Well, OK, pointers beyond "wear safety glasses"?

 

what I do when I need to drill into metal, is put a piece of masking tape on the spot and mark it and drill through the masking tape ...this keeps the drill bit from drifting away.....also start with very small pilot hole and work up....and yes, there are special high quality drill bits for metal ....good luck

 

Just center punch it, with a punch or a nail, and drill it. A hand drill will work
just fine but you want low RPMs on the drill or you will overheat the bit. A
few drops of lightweight oil will also help.

 

imagox- are you talking about the holes you need to make on the bonnet?
if so, i recommend you borrow an electric drill, tape the bit
to mark the depth and then drill using a bit for metal (unless you don't need
to reuse the wood bit). as mentioned above, use some WD40.

if you don't have access to an electric drill, then go to homedepot and..j/k
i would recommend you make that hole using a round file instead. last
thing you want is to drill too deep into the hole and make a hole on the
upper metal of the bonnet.

 

You could also run by a machine shop with your parts marked and someone might be willing to drill a couple holes for the price of lunch.

 

Matt, PM me & I'll loan you a drill & bit for the job.

 

Man, I am SO freaking pumped... a fellow NAM-er (I won't mention his user name, in case he doesn't want to be overwhelmed with PMs ) made me a set of replacement light cradles with a single hole that look like they'll be absolutely PERFECT on the Madness-type brackets. He even put in a set of bends that make the "foot" of the bracket smaller to better match the attachment point, and they look, if anything, even BETTER than the stock ones included by Hella. I swear - if I had the brackets in my possession I'd get started installing them TONIGHT. Thanks man (you know who you are) for turning them out for me - yaaaaaaaay!!!

 

One of the many benefits of NAM membership....helpful folks. Thank you mystery NAMer, whoever you are.

 

Duck-tape!!

It is a must for drilling metal.