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Old 04-06-2011, 03:51 PM
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sphelps sphelps is offline
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Aluminum is definitely one of the easiest metals to drill and tap however when I worked in electronic manufacturing the amount of taps our production staff would break off was astounding. No mater what material once you get into the smaller size taps like 6-32 or smaller it's very easy to break them off, often it's just a result of a little twitch or slip. I myself also rarely have issues but for someone with no or little experience I wouldn't recommend drilling and tapping 100+ holes for the sake of avoiding some soldering.

I do like the idea of using self tapping screws though! I also like the idea of using this type of connectors but I'm not sure it's actually the easiest and quickest route.
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