How To Cut Slotted Holes in Steel with a Drill Press

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This isn't the safest way to cut slotted holes in steel, but it worked surprisingly well. All you need is a drill press, a HSS step drill bit, a file, and some stock steel (or aluminum if that's what you're using). The drill press I was using was a pretty weak one, and the bit got caught a few times, but it wasn't strong enough to pull the steel from me.
If you don't have access to many metal working tools, this will do the trick in a pinch!

Let me know what you think of this method, and if you know of a better way!

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(Formerly Cambridge Drive Inc.)

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Step bits are useful here, but I would use a carbide burr in a drummer to smooth the edges. They are relatively easy to get. That was you spend a lot let time with hand file.

jtbmetaldesigns

Heh. It's really easy to end up in the ER doing it with haste.
For this kind of thing, and I've done what you did here, a die grinder is pretty handy.
Also a good jig saw will work.
For marking things, I like to clean the surface and use layout fluid for marking the workpiece.

stringlarson

Excellent, just what I was looking for.

crunchihuahua

👍 fun video! It worked though. Here is the real question, did you lose any part of your anatomy in the process?

TheDadCave

I had to do something similar to some 1/4 inch thick steel and the slots needed to be 3 inches. I just drilled a hole at each end, then got a metal blade for thick metal for a jig saw. clamped it all down with a fence and cut some really nice slots! Wish I had recorded it. P.S. I'm looking at how to do slots that are small on some soft thin aluminum.

volksbugly