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I'm a Hilti snob afficiando, sorry :) (y)

Perhaps, rather than referring to SDS driils, it would be more accurate to refer to their correct name, rotary hammer drills. The term SDS only really refers to the chuck, and it's particular method of holding the bit.. That said, I'm not aware of a percussion drill that has an SDS chuck. The...

Brilliant (y) (y) Nice to have some good news for a change. Got the lowlife toerags... (y)(y)

Very true. The step drill is my preference for drilling sheet metal. They do not snag, and they leave a very neat hole - also with a nice little chamfer, if you're careful. And no burs. (y) (y)

I agree with you there Stuart. Whilst the question posed is an interesting one, and inspired some thought ; they are hardly worth the trouble of actually trying to make outside of a dedicated production environment. In reality, one will spend perhaps 1 or 2 hours to produce 1 piece, which can...

Actually, forget the step drill suggestion. I just tried it, and it came out the other side 😂 :rolleyes:

Trying to achieve that, when both pieces are the same diameter, is going to tear out the sides of the recieving piece. In the image you have provided, I suspect the two stubs are an inferior diameter to the handle. With that, I would probably use a step drill.

RIP the joke thread :cry::cry:

I'm desperately resisting facetious comments to that bit, apart from saying that what I get up to in the evenings, I like displaying to the wurld that's passing by... :) :) :p

A bit sloppy on setting up the machine (spindle moulder or router). There's room for improvement :unsure: :)

Correct - When it's AC voltage.

As above, Pink plaster... It does exist :)

More to the point, can we smoke it ? :dunno:

If all else fails, maybe put the work on a milling machine. :) Remember, this is wood we're talking about. One piece needs to be fitted to another. It's not about micron accuracy to square, as such. It is about creating a tight, and pleasing, liason between one piece of wood and another. ETA ...

As it's all symmetrical, make a stencil from some stiff card. The stencil should only be one half of the overall form. Then, by the use of a centre line you flip the stencil over to mirror the exact shape on the other side. If that makes sense :unsure: :)

A small amount of awkwardness and discomfort right now, but avoiding an absolute shed load later. (y) (y) Your life will thank you for it. :)

It was also a tremendous example of how democracy can be manipulated and abused.