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Re: More on Drilling

The following is an excerpt from my book,=20
"Book-on-Demand Publishing" is $24, including postage in the U.S. 248 pages,
soft covers. ISBN1-881676-02-1. It is available from several sources,=
the publisher direct from me at 101 W Windsor Rd., Urbana, IL 61802-6697. It
includes info on costs, step-by-step details on printing and binding, and=
on the minimal equipment needed.

Drilling and Punching Paper
        Holes in paper can be produced by punching or drilling. The most=
use of holes is for loose leaf binding, but other types of binding also use
holes of various sizes in different configurations. Most punches won't=
 handle a
stack of paper more than about 3/32" (3 mm) thick, but one exception is the
Acco 650 Mega-Duty punch which puts two or three holes through 100 or more
sheets of 20 pound bond =BD" (12 mm) thick with one strong push on its long
handle (Quill #941-74650, $150). It makes only one size of hole, 9/32" (7=
        Paper drills can go through a stack of paper an inch (25 mm) or two
inches (50 mm) thick as if it were butter. A paper drill is basically a=
drill press with a clamp to hold the paper down. However, an ordinary drill=
designed for metal or wood would tear up the paper, rather than making a=
hole. The drill bit for paper is a steel tube with a countersunk cutting=
The tubes are designed to fit in one and only one of four standard styles of
        Paper drill bits range in size from c" to =BD" in diameter. As they=
through the paper the cut-out circles flow up through the tube and out a=
in its side or top. As they emerge they are deposited in a receptacle from
which they are removed periodically. Some drill bits are coated with teflon,
which reduces the heat and smooths the passage of paper through the drill.=
cost about $20 each from Printers Shopper.
        Drill bits for paper get dull after a few hours of use, but they can=
resharpened easily. A carbide 60 degree =BD" diameter countersink does the=
they are available from mill supply stores for about $35. Countersinks with
handles or cranks are sold by Printers Shopper from $36 to $100.=20
        Both paper punches and paper drills are available to cut several=
at the same time. Three hole punches which make =BC" holes are for sale at=
office supply store for about $30. Better punches allow the distance between
holes to be adjusted, and allow one, two, or three holes to be punched at=
same time. Paper drills which make one hole at a time cost $600 or more;=
spindle machines are considerably more expensive. Still more expensive=
are fed through the paper by hydraulics, rather than by the more common hand=
foot feed.

Making a Paper Drill
        If you have a drill press with a =BD chuck and have access to a=
cutting lathe, it is possible to make your own paper drill quite=
There are four key parts to a paper drill: the mechanism for rotating the=
bit and for pressing it through the paper; the drill bit; the hole catcher;=
the clamp to hold the paper down when the drill bit is withdrawn.
        The drill press supplies the mechanism for driving the drill bit.

(Insert the attachment here)
Figure 10-2 Paper Drill

        If you have access to a metal cutting lathe, you can easily make the
drill bit and the hole catcher by following the dimensions shown in Figure
10-2. The drill bit is made from =BD" diameter drill rod. It is cross=
using a c" drill, a =BC" drill, and a d" drill. Drill and ream hole B before
turning diameter A. If you ream after turning, the outside diameter will be=
        I like to keep four sizes of paper drills on hand, with hole B being
1/8", 1/4", 5/16", and 3/8". In each case, diameter A is .020" larger than=
        Form the cutting edge by countersinking hole B. It is not necessary=
harden the drill.
        There is only one critical dimension on the aluminum hole catcher.=
half-inch hole should be reamed or bored to .500=B1.001". If the drill is=
 not a
light press fit in the hole catcher, join them with an anaerobic sealant=
as Loctite, or lightly knurl the drill. Assemble these two pieces so that 1"=
the drill extends beyond the hole catcher, where it can be grasped by the=
press chuck. Chips will escape through the cross-drilled hole and be caught=
the hole catcher, which fits against the bottom of the drill chuck.
        A 3/8" paper drill should be run at about 1000 RPM, while a 1/8"=
works best at about 3000 RPM. If the drill changes color to dark brown or=
it is either turning too fast or it is dull. Put a piece of hardwood,
preferably end grain, under the paper to be drilled. Mark the places to be
drilled, using a ruler and pencil or a sheet of pre-punched paper.
        If you are going to drill several holes, build a fence and stops to
locate the paper. A presser foot, either cam actuated or spring-loaded, is
needed to hold the paper down while the drill is being withdrawn from the
paper. A standard cam-operated clamp which fastens to the column of the=
press works fairly well, but a better device is spring loaded, with the=
being compressed as the hole is drilled. The springs continue to hold down=
paper until the drill is fully withdrawn,=20

At 11:48 AM 5/29/1999 -0400, you wrote:
>Please make these directions available to the book list in general, if you
>can.  If not, would you please send a copy to me?
>Susan Lightcap
>Vessels of the Spirit
>2 Wall St., Suite 106
>Asheville, NC 28801
>828 232-0202
>At 10:37 AM 5/29/99 -0500, you wrote:
>>If you have access to a metal lathe, I can send you directions for making=
>>proper paper drill, which cuts very cleanly by removing a core of paper.
>>This bit is used in a standard drill press, and produces a much better
>>result than do bits designed for wood or metal.

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