Using the right drill lets a department keep on trucking: when 200 holes have to be drilled into a truck chassis to customize it for heavy-duty work, time can't be wasted fussing with a lot of tool changes or dealing with cranky equipment. Finding the right equipment decreased drilling time by 80 percent.

Customizing a heavy-duty work truck chassis for specialty use means drilling holes to accommodate added axles, fit beefier suspension components, add cross members, install electric braking systems, and create other modifications. Putting those holes in the right locations as efficiently as possible was the goal of a manufacturer's modification department when it went looking for a better way to drill.

The workhorse trucks used for construction, short hauling, refuse collection, fire, snow removal, municipal functions, oil delivery, and concrete pumping have different requirements according to their role. It was the job of the customizing group to make sure the frames were prepared for the modifications.

"Each variety of truck has different variables and each customer will have their own specifications, dimensions, and modifications that can't be done on the production line," the department supervisor said. "The work has to be done as fast as possible while maintaining high-quality standards. Inconsistency is the only constant element of the work."

The one consistent part of the work is drilling holes from 3/8" to 1-1/16", cut through frames that are 3/8" thick, or in some cases, through frames lined with a 1/4" second layer. The department tried several methods, but each had drawbacks.

First: Too Hard

A pedestal-mounted drill motor and twist drills were first used to modify the frames. The drill was usually chained to the frame and was difficult to position and secure. For setup, the shop floor had to be cleared of tools, hoses, cords, and equipment so the pedestal could be maneuvered around the chassis. Drilling was cautious and slow to prevent the drill from grabbing, twisting, and torquing the motor as the tool broke through the frame.

Those problems were compounded by short tool life that slowed the process and added cost.

Second: Too Slow

To alleviate these problems, a portable drill was tried. That method solved the positioning problem, but was underpowered for making large-diameter holes. The portable drill required three tools and operations: First a pilot hole had to be drilled. Second, another bit had to be used to rough-size the hole. Third, a reamer was needed to finish-size the hole. The portable drill proved as slow as the pedestal drill, with the added disadvantage of three tool change-outs.

"We had one job that involved chassis modifications, which needed more than 200 holes. It took us four days," the supervisor said.

While there are no typical jobs in these customizations, there are an average of 40 holes that have to be drilled in each frame being modified.

Third: Just Right

After some research, the department tried a Hougen HMD115 portable magnetic drill with RotaLoc annular cutters. The low-profile drill proved to be just what the department needed.

The drill and cutter combination reduced drilling times up to 80 percent. Jobs that once took four days were finished in one. The portable drilling system cuts nearly burr-free holes, reduces deburring tasks, and contributes to a safer work environment with less manual effort.

The department supervisor said the drill from Hougen, Flint, MI, handles easily. When the drill's magnet is engaged, the drill is securely held to the frame, providing hole location accuracy. The RotaLoc cutters drill even large holes in one pass.

The HMD115 was originally designed for the truck frame industry and has now found wide use in job shops and small contract manufacturers.

The drill measures 6-11/16" high, 8-1/2" wide, and 11-3/4" long and fits into spaces where traditional hand-held drills cannot, allowing users to work in confined areas such as behind tire and rim assemblies without removing wheels.

The drill weighs 21.3 lb and cuts holes from 1/2" to 1-1/16" to a 3/4" depth. It has a 7.2-amp motor that operates standard 115VAC with a no-load turning rate of 450 rpm.

A Magnetic "Personality"

The drill's magnetic base measures 4"x7" and has a deadlift rating of 1,283 lb on 3/8" plate. Controls include separate magnet engage/disengage and motor spindle on/off switches. The drilling switch must be continuously depressed during operation.

The cutters are the other factor in the success of the drilling operation. The Hougen RotaLoc annular cutters cut holes faster than conventional twist drills previously used by the customization department. The cutters have a proprietary tooth geometry.

The cutters do not have a center point, so cutting takes place at the periphery of the tool and evenly distributes the cutting load. The cutters' stack-cut tooth geometry lets the tools cut through the doubled-up chassis frames without interference.

"The performance has been so good," the department supervisor said, "that it justified the purchase of a second unit." Hougen

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Drill Sharpener Keeps Bits Keen

The Darex XT-3000 manual drill and tool sharpener accepts drill diameters from 1/8" to 13/16", 2" minimum length with no maximum, has an adjustable point angle range of 118[degrees] to 150[degrees], meets or exceeds National Aerospace Standards for lip height variation, uses an Emerson 1/4 hp - 3,450 rpm - rated for continuous duty, and weighs 60 lbs. The sharpener has a sharpening wheel and a point split wheel with CBN or diamond wheels available. No tools necessary for any adjustments on the machine or attachments. Darex Corp.

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Shorter Boring Head Offers More Rigidity

An integral-shank design for the EW2-50XL provides a lighter and more rigid boring head. It is available for CAT40, BT40, HSK-A63, and Capto C6 size spindles and provides a shorter tool than the modular shank and boring head combination. In the case of the CAT40 taper, the tool is 1.3" shorter, which translates into a tool that operates at higher cutting speeds and feeds. For use with existing center-mounted boring bars 0.078" to 2.125" and side-mounted insert holders 3.15" to 6.00", these heads can be used for precision finish boring with a large adjustment dial displaying increments of 0.0002" per dial division and Vernier markings to accurately adjust to 0.00005" diameter accuracy. Additional accessories for the EW2-50XL heads allow for counter-boring, back-boring, chamfering and even O.D. turning with stock-standard components. BIG Kaiser Precision Tooling, Inc.

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Color-Coded Burs for Different Metals

A line of specially-coated TC burs with anti-friction properties are available for high stock-removal or fine machining and deburring. The Hicoat tungsten carbide burs offer superior chip removal, reduced tool wear, and lower heat loads when working on metals, such as hardened, heat-treated steels and heat-resistant alloys such as cast iron and soft, nonferrous metals. The proprietary coatings on the burs provide an anti-friction quality. Because the burs are rated for operation at higher rotating speeds, their productivity is increased and service life is extended. The burs are available in three coating types and in a variety of shapes, cuts, and sizes. They are also color-coded to identify the material on which each works best. The HC-FE is colored gold for steel and cast iron. The HC-HT is colored silver for heat-resistant, nonferrous metals such as aluminum, brass, copper, zinc, or nickel-based alloys. The HC-NFE is black for anti-adhesive coating for sticky, non-ferrous metals that produce long chips when machined or cut. The bur shapes include ball, tree, pointed tree, cylindrical, and conical and the cuts available are 1, 3, and 3 plus. Pferd Inc.

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Boring Tools Customized to User Requirements

Modco Tipped Tools are for reaming, fine boring, and milling. The tools are designed and manufactured to specific part, process, and application requirements. They can be engineered with maximum tooth density for any specified diameter, providing high strength and rigidity for running at elevated cutting speeds. This translates to reduced machining times. No tool presetting means reduced setup time, minimum run-out, maximum tool life, and consistent quality. The tools can be engineered with either steel or carbide bodies, and fitted with advanced PCD tips for aluminum and other non-ferrous materials, or with CBN tips for iron jobs. Tools with worn or damaged tips can be reconditioned by the manufacturer. Valenite LLC 

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