Multifacet parabolic solar concentrator

Step 3 Drill, drill, drill

Now that all of the measurements are made, measure some more and then drill some holes.

Measure halfway in between the 6 3/8 inch intervals on the first, last, middle, and 1/4, 3/4 up each bar.
These will be the holes for the cross-beams.

Now, each of the dimples that was made will be drilled out with a 3/8 inch drill bit. This is a lot of drilling and I highly recommend an electric drill and some understanding neighbors. It will be loud because the aluminum will ring as you drill. That's ok. Also, because you're using power tools, don't forget to keep your fingers clear and your eyes protected. I got a piece of aluminum in my eye once. I do not consider eye injury to be an important step for completing the project, so wear eye protection.

Once drilled, you will want to file the holes flush because aluminum is soft and as such creates lots of sharp edges when you drill it out. An ordinary file will help you remove those edges so you don't slice your fingers.

Comments

[voxelman]

Use a countersink bit or larger drill bit to cleanup the edges of the holes. It will go faster then filing and provide a neater apearance.