Alibro
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Err yes, less vicious (pun intended) in an ideal world we would use a perfect shaped drill and would stop in time to avoid hitting the disks but in my case they get hit and who knows what swarf ends up in side. That's all part of the compromise doing it this way. There are other comprises doing it by cutting and welding. As for the drill size it depends on what thread bolts/nozzles you plan to use. Standard thread uses a smaller drill than fine or extra fine as the grooves made by the tap are deeper. There are tables available to tell you what to use.Presumably you meant to write "The fluid in this one is much LESS viscous".
Incidentlly, I'm sure this has been said before and I could find it searching through an umpteen page VCU thread, but what size holes do you drill and how far in from the edge of the VCU are the hole centers? Do you used "normal" drill bits, or a form of more 'flatter tipped' so as not to damage the plate on the inside of the case?
I pick a spot half way between the shaft and the edge to drill. Go to near the edge and you'll hit the side wall, to near the centre and the bolt won't fit.