So, todays task is to drill 6 equally spaced holes through the stick push tube and threaded rod end. The over lap is 1/2" so the holes are 1/4" from the end of the tube.
As for the spcing between the holes, here is what I measured. Circumference = 3 9/16" = 57/16". 57/16" Divided by 6 holes is 9.5/16 = 19/32". So, the hole spacing for 6 holes is 19/32"
I just made a simple template from paper and wrapped it around the tube 1/4" from the end and marked the hole locations.
Now as for drilling. Use a center punch for sure. I used my Avery Tools spring loaded punch.
Then I drilled the holes using a 3 bit process. 1/16" bit, #40 bit and finally a #30 bit. Image 2 shows all 3 bits. I clamped the tube as shown in image 1 then drilled the first hole with all 3 bits and riveted it. This one rivet will hold the threaded rod end in place for drilling the remaining 5 holes. I used the 3 bits on each hole before moving on to the next hole rather then drilling 5 holes with the small bit then 5 holes with the medium bit and so on. Lots of bit changing here but I only had to line up the hole once and I got smooth centered holes. I guess you can decide if you want to change lots of bits or reposition the tube a bunch. I think positioning the tube once for each hole is better.
Don''t forget to debur the holes.
I dipped each rivet in primer before pullig it. I actually prefer my cheap $5.00 Harbor Freight puller over my Stanley. It's lighter, and seems to have more leverage. Funny thing.