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I want to screw aluminum to wood. If it was wood to wood, this bit:

https://d2pbmlo3fglvvr.cloudfront.net/product/full/Z1K9wvfo5oy.JPG
Image from zoro.com

makes perfect sense for the pilot and counter sink. However, it makes no mention of if the counter sink part would handle aluminum.

Alternatively, should I use this 1/2" Ryobi countersink:

http://www.homedepot.com/catalog/productImages/400/20/20258340-a7f8-4078-9071-5d3534cd125f_400.jpg
Image from Home Depot

and a separate drill bit for the pilot hole?

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  • By "screw aluminum into wood" you mean "put a screw through a hole in aluminum to fasten it to wood", right?
    – Daniel Griscom
    Jun 3, 2016 at 21:57
  • Yes. The screw is a normal zinc screw.
    – Justin Dearing
    Jun 3, 2016 at 21:58

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Generally speaking you can use the same tools you'd use for wood to work with aluminum. I've done a number of projects using aluminum bar and angle stock with my woodworking tools, including a miter saw.

However, since the metal is much harder, you'd probably have an easier time doing the drilling and countersinking separately. I'd drill with a standard high-speed bit, and use a countersink like the Ryobi you linked to finish.

On a related note, you'll not have much room for error when countersinking 1/16" stock. You might be better off with pan-head screws.

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  • My main issue, which the guy at the hardware store warned me about, is I drilled too fast and aluminum shavings stuck to the bit like melted wax. My second issue was it took to long at the slower speed on my drill.
    – Justin Dearing
    Jun 3, 2016 at 23:54
  • @JustinDearing - Too fast shouldn't have been an issue, drilling for too long is though (a kind of work-hardening). You weren't pushing hard enough to make chips; you were galling it. But as mentioned don't push too hard ;) over-countersinking aluminum is my usual problem.
    – Mazura
    Jun 4, 2016 at 0:26
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    The tapered style drill bits need to be handled very carefully when drilling through aluminum. They have a tenancy to want to pull themselves down into the drill hole with a surprisingly aggressive force. So use care to clamp down the work piece and get both hands securely on your drill before starting the hole.
    – Michael Karas ♦
    Jun 4, 2016 at 3:43
  • True. Same with DeWalt's pilot-point bits. the primary cutting edge grabs hard with its square edge profile.
    – isherwood
    Jun 6, 2016 at 14:39

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