(My dad worked for Royal Enfield for a little while. I had a poster of a RE Interceptor on my wall for ages.
When I was 19 I had a Royal Enfield Constellation, 700cc twin. Awesome bike, Bonneville eater in its day. Only problem was I didn't have a full licence at the time so didn't ride it much. The very late Interceptor (I think it was designated Mk2) was truly awesome. Not many made before the factory closed in about 1970. Had an odd arrangement for the foot rests, which were welded to the exhaust pipes.
 
Eye hassa 5.5mm diameter hole in somefink which needs the hole opening up so its centre is moved 3mm along. Last time eye tried to drill anuvva hole inner hole eye nearly lost me finger. Tis 1.6mm steel. Gittid 10 holes to do. New holes is 5.5mm diameter anorl. Wot would be yer preferred method?

Piller drill and 5.5mm bit un clamp metal tight. Take it slow and hope a sharp bit bites frew?

Use a side cutting bit?
 
Eye hassa 5.5mm diameter hole in somefink which needs the hole opening up so its centre is moved 3mm along. Last time eye tried to drill anuvva hole inner hole eye nearly lost me finger. Tis 1.6mm steel. Gittid 10 holes to do. New holes is 5.5mm diameter anorl. Wot would be yer preferred method?

Piller drill and 5.5mm bit un clamp metal tight. Take it slow and hope a sharp bit bites frew?

Use a side cutting bit?
File it with a half round file.
Then drill the others where they ought to be drilled.
 
Eye hassa 5.5mm diameter hole in somefink which needs the hole opening up so its centre is moved 3mm along. Last time eye tried to drill anuvva hole inner hole eye nearly lost me finger. Tis 1.6mm steel. Gittid 10 holes to do. New holes is 5.5mm diameter anorl. Wot would be yer preferred method?

Piller drill and 5.5mm bit un clamp metal tight. Take it slow and hope a sharp bit bites frew?

Use a side cutting bit?
Dremel type tool with rotary burr bits, possibly.
 
Eye hassa 5.5mm diameter hole in somefink which needs the hole opening up so its centre is moved 3mm along. Last time eye tried to drill anuvva hole inner hole eye nearly lost me finger. Tis 1.6mm steel. Gittid 10 holes to do. New holes is 5.5mm diameter anorl. Wot would be yer preferred method?

Piller drill and 5.5mm bit un clamp metal tight. Take it slow and hope a sharp bit bites frew?

Use a side cutting bit?

Step drill
 
Either of the above or gets it on a milling machine (or pillar) wif a slot drill.
Needs to be fixed in place though.
Poisonally I'd go for Stans file.
He just needs to mark up carefully on the workpiece with a Sharpie, then file carefully, as a file is a bit of a "blunt" instrument if not used with care.
I'd also clamp it between a coupla bits of wood as 1.6 is a bit thin.
Slow and steady, with much checking, wins the race. ;)
 

Similar threads