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Thanks to everyone who responded. Because of the piece of rod I was drilling I had to use a 90-degree adapter. This allowed me to get a slightly better view of the drill vs. work to make sure the bit was perpendicular to the work. I did have the rod in a vise and I even ground flat the section I was drilling to make it easier to start penetration. I used some 20w engine oil, medium drill speed (my gut feeling said faster would be better than slower with the small bit, glad I listened), light-to-medium pressure (what?, you haven't seen that measurement on a torque wrench before? ;), and would just oil, drill several seconds, wipe all parts, re-oil, and repeat. I know the cutting angles are important so I wouldn't try to sharpen them myself...I'm not that bored :) It's easier and faster to just buy a new one. So I now have my Mesa oil cooler installed in the Squareback. Oil lines and electrical are next, but the hard part is done. Man oh man, I can't believe how much time it took me to measure, test fit, measure, test fit, etc. - that was the big time sink - until I finally got it in. But now it fits great, totally clears the starter AND the flexible hose between the heat exchanger and body, so if later on I want to re-install my heat exchangers I can without worry. Of course, I doubt I'll be doing that since I *just* received my ceramic coated 1.5" collector exhaust <Dr. Evil laughter in the background>... Toby Erkson air_cooled_nut@pobox.com <-- Please use this address for email '72 VW Squareback 1.6L bored and stroked to 2.0L, Berg five-speed '95 VW Jetta III GL 2.0L, P-Chipped, Jamex sport suspension Portland, Oregon, http://www.pobox.com/~toby_erkson/ >-----Original Message----- >You need to hold the rod (like in a vise) so that it doesn't move on >you, and you need to maV摇4that you are pushing the drill >STRAIGHT into the work. > >The speed needs to be rather high for this small a bit (to keep the >cutting speed up) just as you need to slow down when drilling a large >hole. > >Any kind of coolant is better than nothing. You can use, LPS, WD-40, >3-in-1, motor oil, or water. > >The drill needs to be sharp, and it is VERY difficult for the novice >to sharpen bits by himself, especially the small ones. ... ------------------------------------------------------------------- Search old messages on the Web! Visit http://www.vwtype3.org/list/