How do I drill a hole in the factory roll bars?

[SteveInOrlando]

OK, I need your help! I tried installing hard grab handles in the back seat today, and I need to drill a small hole in the roll bar.

Sounds simple enough. Remove top, remove cover from roll bar, carefully mark the hole, center punch, and drill. Except, I can't find a drill bit that will cut into the metal. I have tried new carbide tip and the general steel cutting bits. They cut the paint, but no damage to the metal underneath.

I know roll bars are hard steel, but I have never had a problem drilling a hole before. Anybody got an idea?


Thanks,

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[chorky]

Try a cobalt bit. Theyre quite a bit harder and not as expensive as a diamond tip.
also use some wd-40. Oil makes cutting way easier!

 

[Animal]

Here's some intro from rock hard 4x4 on drilling to install their roll cage.

"Drilling - every RH-90700 Cage Brace System includes a "Drill Bit Pack": 2 special hardened drill bits and a special "die grinding tree". Why 2 drill bits? Because odds are, you'll need 2. The new factory cage material, while only 14 gauge, is hardened. It takes a very slow (300 RPM ideal, 500 RPM max) drill process and a special hardened cobalt drill bit to penetrate. Your big box store drill bits will not work. The die grinder tree will help you remove burs and finish out the holes. You aren't required to purchase, but may very well need, an additional Drill Bit Pack."

Here's a link to their bit kit

https://www.rockhard4x4.com/product_p/rh-90710.htm

 

[toddarama]

300 RPM ideal, 500 RPM max

Don't ignore this part of their guidance. Drilling hardened steel is a situation where faster isn't better. High speeds will just overheat your bit. WD40 won't hurt, but you could probably get a small bottle of cutting fluid at a hardware store to help.

 

[OHJeeper]

Try a cobalt bit. Theyre quite a bit harder and not as expensive as a diamond tip.
also use some wd-40. Oil makes cutting way easier!

+1 for cobalt. They cut like butter compared to the carbide and bi-metal stuff.

 

[steve68]

Use the right speed and the right cutting fluid,

I like Rapid Tap cutting fluid, but Lowes has there own brand that works really well, I was actually impressed with it,

 

[ShadowsPapa]

WD40 isn't a lube. IT's crap for drilling and mill work. Even makers of high-end motorized equipment (like a $20,000 quilting machine) say use it to clean, then use real oil "Wd40 is not a lubricant". It's fine for hinges - but not for real work.

Cutting oil - it's not the same as other oils.

Carbide bits - let's just say I've busted a few carbide lathe tools and bits. Not great for hardened steel.

Good advice above - slow speed is a YES, cutting oil is a YES, and cobalt bit. Skip Menards and Home Depot for bits that you need to do real work.
I've destroyed carbide topped cutting tools on hard steel. A cubby under my lathe is loaded with 'em.

 

[Rusty PW]

I have cobalt drill sets. Their are not cheap, but worth it. I've used them to drill through Inconel's, monel's, hastelloy, etc. And use a good cutting fluid.

https://www.grainger.com/category/machining/drilling-holemaking/drill-bits/drill-bits-for-metal-plastic/drill-bit-sets/jobber-length-drill-bit-sets?attrs=Material+-+Machining|Cobalt&filters=attrs&categoryIndex=2

https://www.grainger.com/search/mac...ting+fluid&searchBar=true&tier=Not+Applicable

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