How to Fabricate Small Diameter Holes

Step-by-Step Guide

1. 1

   Step 1: Use a conventional twist drill to make a hole that is six to ten times the diameter of finished hole diameter.

   In this case, for a finished hole of .005" the hole might have a diameter of .062".
   
   This is possible using a standard hand drill or drill press.
2. 2

   Step 2: Prepare some epoxy

   One product that works is called called PC-7 (for high heat applications). ,, Leave some wire to grab on to.
   
   Use as short a piece of wire as possible to keep it lightweight.
   
   Position the wire as close to the center of the drilled hole as possible when putting the wire into the soft epoxy putty. ,,
3. 3

   Step 3: the kind that is like putty.

4. 4

   Step 4: Fill the hole that was drilled with an amount of epoxy putty to create a plugged hole.

5. 5

   Step 5: Using a piece of piano wire or guitar string of the desired hole diameter

6. 6

   Step 6: coat with some motor oil or grease and gently push the wire into the putty that is in the oversized hole.

7. 7

   Step 7: Allow the epoxy to harden as per instructions.

8. 8

   Step 8: When the epoxy has hardened carefully pull the wire (using pliers or grippers) from the epoxy to expose the small diameter hole.

Detailed Guide

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