New2CNC.COM: Drilling Clonedel Prusa parts.

Drill Clonedel Parts
SAE

Warnings and general advice.

Divots in parts match intended drill bit size
Pilot holes are not recommended as they increase the likelihood of damaging parts during drilling.
Clamp all pieces down prior to drilling to avoid the part getting away from you.
A drill press vice would be ideal.
On thin pieces drill slowly and do not dry to entire hole in one pass. Use compressed air between plunges to clean out dust and debris.

General guidance on drill bit sizes for Clonedel version of SAE Prusa Mendel :

Frame Parts and drill bit sizes

Part	Image	Bit size and directions
coupling		test fit ends on motors, one side is already snug for the 5mm shaft so no need to drill. The other side should be drilled out with 5/16 bit halfway down. divots on face for #6 screws, use 9/64 bit
endstop-holder		9/64
x-carriage		9/64 May not even need to drill, just press out any excess coating
x-end-idler		5/16 trapped nut hole in top plate, side of bottom plate 9/64 aligned bottom/top plate holes
x-end-motor		5/16 trapped nut hole in top plate, 9/64 aligned bottom/top plate holes and motor mount holes in bottom plate
y-motor-bracket		5/16 for threaded rod holes 9/64 for motor mount holes
z-motor-mount		5/16 on ends for threaded rods 9/64 on ends meeting trapped nuts Don't try to drill the entire threaded rod hole in one push.
belt-clamp		9/64
bar-clamp		9/64 Slide scrap smooth rod into bar clamps and end stop holders to stabilize them during drilling
rod-clamp		9/64
pulley		5mm for motor shaft 4-40 tap for set screw
frame-vertex with foot		5/16
Frame-vertex		5/16
pla-bushing		No drilling necessary.
Wade's Extruder
Extruder Block		5/16 in side for hobbed bolt 5/32 for M4 bolts alligned with idler 9/64 through top for fillament, through bottom for mounting to x-carriage
Extruder Idler		5/32 for M4 bolts
11t gear		5mm for motor shaft 4-40 tap for set screw
39t gear		5/16 for M8 bolt