[lekkaut]

Hi All,

This year I've picked up metal working, in particular metall milling and turning. For a project I want to connect 2 aluminium bars together with a press fitting connection of two dowel pins. Please see the picture to understand the design. I'm no expert in metal working at all and I think this type of connection will be difficult to build, because of accuracy challenges.

I'm planning to use a 6mm H7 reamer to drill the holes exactly to the right size. The steel dowel pins should be 6.000mm which should result in a nice press fitting. I think the
positioning of the 2 holes in each end of the 2 aluminum bars will be the biggest challenge:

1. How can I drill holes in the ends of these 2 long alu bars with enough accuracy?
2. Are there other aspects I should take care of before I start drilling?

Any idea's, comments and tips are highly appreciated! Thank you.