What is the best method for boring large holes in aluminium bar?

[Blakelidge]

Well, I suppose I'm lucky in being a child of the 70's in that I was tutored in imperial and was there when metrication came in so I was schooled in that also, but I agree that working in both can lead to confusion. I do tend to flip between the two, haha, sometimes even on the same measurement, I have been known to ask for stuff like, cut me a piece 2mm over 18" please.

I originally sourced my alu from metals4u, but for reasons of the alloy and the markings caused by the extrusion process mean that the anodised end result is not flawless (but not terrible either)

According to a table I read on various alloys, (http://www.asminternational.org/pdf/...eets/al392.pdf) it seems 6061t6 or 6063t6 is my ideal metal.

You are right in saying that 2" with 1/8" wall is commonly available, and that is what I use for the inner part.

I am struggling to source however a tube to cover my needs of 53.8 finish OD and ID of 48.8mm. This would equate to a tube of slightly over 2 1/8", so 21/4" realistically and the OD of this is 57.15mm so take away 2x3mm wall and it is too baggy on my first part. So it would have to be a tube 2 1/4 with min of 1/4" (6mm ish) wall to suit. I can't find a tube at 2/14" x 1/4" in 6061 or 6063 alloy anywhere, this is why I feel I'm stuck with the problem of all that machining.

Also, thanks for the offer to forward supplies on to me, it's appreciated.

If this were a timber project, I could easily use a holesaw to remove the inner waste from the timber. I assume there is no equivalent to a holesaw in the metalworking world? would be cool though as I could also use the resultant slug instead of my current useless mountain of shavings

Regards

[ger21]

I've drilled aluminum plate with a hole saw. Maybe one of the single carbide tooth type might work for you?

[kawazuki]

Try here?

http://www.m-machine-metals.co.uk/Ca...c_MAY_2008.pdf

they list 1 3/4" upto 1/4" wall and 2" dia upto 1/2" wall? Worth a call in case?