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How do I drill large holes in aluminum extrusions?

How do I drill large holes in aluminum extrusions?

How do I drill large holes in aluminum extrusions?

(OP)
Reposted from "Fabricated Metal Product Engineering Forum":

We are using aluminum extrusions for commercial garage door frames such as in a firehouse or service station garage.  To fasten them together in the frame shape we have to drill holes through the horizontal ones and fasten through them into the vertical ones.

We currently drill the horizontal extrusion with the fastener hole on edge mating against the vertical.  We then take the horizontal piece and on the opposite side of the fastener hole we use a hand drill with a hole cutter on a pilot bit.  We saw a hole that is nearly 1" in diameter.  This allows us to insert the fastener with a socket and extension on an air impact wrench.  But this is time consuming as the slug needs to be taken out of the hole cutter most every time.

I am looking for a large bit such as a "bullet point" style that would shave away the material with out leaving the round slug.  The extrusion walls are about 1/8" thick but there is ribbing structure to go through for 1" of depth as well.  The hole we need has to be greater than 3/4" dia. and at least 1" deep before we are fully clear into the hollow of the extrusion.

Davey

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