Drilling 1mm holes through cap head bolts
I suppose the title says it all, but a bit of background might modify the possible answers.
I'm prototyping a new style of tuning pin for a multi-stringed musical instrument.
I want to keep the costs rock bottom as I'm proposing to donate them to local schools to encourage an interest in music making.
Part of the tuning arrangement has finished up as a M5 x 25mm cap headed bolt, with a 1 -1.5mm hole drilled sideways just under the head.
This is the primary anchor point for the steel string.
Stainless would have been nice, but the near impossibility of drilling 25 bolts per instrument rules that out.
The bzp bolts I have tried seem to be case hardened, but that seems to be the only way I can go forward.
I'm thinking along the lines of either using a small grinding wheel in a dremel type drill to make a small flat, and cut through the outer layer, or heating the whole batch up red hot to anneal it, but then that would mar the appearance somewhat.
Any ideas would be welcome, along with any information that seems to fit the problem.
John
It's like doing jigsaw puzzles in the dark.
Enjoy today's problems, for tomorrow's may be worse.