Since my VS-808PP spar doubler is trashed anyway, I decided to use it to experiment drilling lightening holes by other methods. I bought a 2" hole saw from Lowes and mounted in my Craftsman table-top drill press. It drilled through the aluminum much faster than the fly cutter, but I'm still not satisfied with the results. As the hole saw rotated in the chuck, I noticed that it was not spinning in a perfect circle, and the drill exhibited some run-out. After drilling the hole, I measured it and found it to be 2 1/16th inches in diameter. Not good. So, I can either leave the part alone and not drill out the lightening holes, or I can invest in a better drill press with no run-out. It's all about choices, huh? I've got a couple days to think about it while I wait for my new VS-808PP to arrive from Vans.
