12 Tips For Drilling Holes In Metal - The Family Handyman

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Home Skills Metalworking Drilling 11 Tips To Make Drilling Holes In Metal Easier and Faster

By Ethan O'Donnell

Family Handyman's Editorial Process

Updated on May 28, 2025

For most DIYers, there will likely come a time when you'll have to learn how to drill into metal effectively..

Drilling through metal can be somewhat intimidating for beginners, but there’s nothing to worry about. It’s just as easy as drilling a hole into the wall or wood, but there are a few additional considerations.

Whether you’re working with thin sheet metal or need drilling tips for thick steel, this guide covers how to drill into metal effectively, incorporating essential safety measures, tool selection and techniques vetted over decades by the editors at Family Handyman in our shop.

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Safety Considerations for Drilling Through Metal

• Wear safety glasses: Drilling into metal produces tiny, incredibly sharp fragments that can cause a serious eye injury, which means proper eye protection is a must. Choose safety glasses that wrap around the sides of your face for maximum coverage.
• Wear work gloves: Metal shards can also cut the heck out of your hands, so we highly recommend durable work gloves.
• Clear chips safely: Always reach for a workshop brush instead of sweeping them away with your fingers—those tiny metal slivers can cause painful cuts that are easily avoidable with the right tool.
• Handle hot metal carefully: Metal can heat up due to friction from all the drilling; so either allow it to cool or use pliers or gloves.

Now that you understand the safety requirements, let’s explore exactly how to drill into metal with precision and ease.

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Choose the Right Drill Bit

Almost any general-purpose twist bit will do a decent job of drilling holes in metal. In fact, most drill bits labeled specifically for metal are manufactured to drill through various materials, including wood and plastic. The least expensive twist bits are made of high-speed steel (HSS), and these basic bits are just fine for most common metal-drilling tasks.

However, if your project demands repeated drilling or involves tougher materials, upgrading your toolbox makes practical sense. For example, high-quality cobalt bits may cost more initially but deliver superior performance on harder metals and will bore more holes before becoming dull.

Some bits also have a special coating called titanium nitride (TiN), which manufacturers claim helps resist heat and friction better, making these bits last up to six times longer than standard high-speed steel bits.

For most metal drilling projects, bits with a 135-degree split point design will make your job much easier. This helps prevent the bit from walking when starting the hole and requires less force—especially when working with harder metals.

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Make a Dimple

Drill bits have a tendency to wander when you first start drilling. To prevent this, measure and mark where you want the hole and then use a center punch and hammer to create a small dimple. This gives the tip of your bit a place to ride in as you begin to drill.

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Use Cutting Oil to Prevent Overheating

For drilling holes in steel that’s 1/8 in. or thicker, use cutting fluid or a multipurpose oil. Lubricating the bit reduces friction and heat buildup, which makes drilling easier and your bits last longer.

For easier-to-drill metals like aluminum, brass or cast iron, lubrication isn’t usually necessary.

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Use Clamps to Secure What You’re Drilling

Never hold a piece of metal in one hand while trying to drill through it with the other. The drill bit for metal could catch, causing the workpiece to spin, strike and slash (sharp metal edges slice to the bone!). Always use a minimum of two clamps to secure your workpiece.

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Start With a Small Hole

Need a big hole? Start small! Most twist bits are available in sizes up to 1 in. in diameter, but you’ll get the best results by starting with a 1/4-in. hole and drilling successively larger holes with your drill bit for metal until you reach the size you want.

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Deburr the Hole

​​The finishing touches for drilling into metal include proper cleanup of the completed hole. It’s a good idea to remove any sharp edges or burrs left behind.

You can buy fancy deburring tools to smooth sharp edges, but before spending money on one, try this trick: Take a twist bit slightly larger in diameter than the hole you just drilled and gently hand-twist it over the top of the hole. This will help smooth out the edge of the hole and grind away any burrs.

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Hole Saws Cut Bigger Holes

For large holes (typically over ½ in. or 1 in.), a hole saw gets the job done cleanly and quickly, as long as you use one rated for metal. Like twist bits, hole saws chuck right into your drill and will cut through thin-gauge sheet metals like aluminum and steel.

Make sure you use the right technique for a hole saw. Use a scrap of plywood as a backer for the hole saw’s pilot bit and to protect your work surface.

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Drill at a Slow Speed

Slow down! The faster a bit spins, the hotter it gets. And heat dulls bits quickly. In general, it’s a good idea to drill through metal using as slow a speed as possible using a drill bit for metal. Hard metals like steel and larger drill bits require even slower speeds. With a small twist bit (1/16 in. to 3/16 in.), you can drill through most metals at 3,000 rpm. For larger twist bits (11/16 in. to 1 in.), 350 to 1,000 rpm is recommended.

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Make a Sandwich for Thin Metal

For clean, precise holes in thin sheet metal, make a wood sandwich. Simply sandwich the sheet metal between two pieces of wood and clamp everything down on a table or workbench.

The wooden ‘bread’ layers of the sandwich keep the sheet metal flat and prevent the drill bit from wandering as it bores through the sheet metal. This technique improves accuracy while also helping with how to prevent overheating while drilling into metal sheets.

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Drilling Tips for Thick Steel

Drilling tips for thick steel include using even slower speeds, applying more cutting fluid and maintaining steady pressure. For steel plates thicker than 1/4 in., consider drilling from both sides when possible to maintain precision and reduce strain on your tools.

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Try a Step Bit

Step drill bits are designed to drill holes in sheet metal and other thin materials. They’re just the thing when you need a perfectly sized, clean hole in a steel junction box, electrical service panel or even a stainless steel sink. A step drill bit for metal allows you to drill holes in a variety of diameters and some will drill through metal up to 3/8 in. thick. The downside? Step bits are more expensive than regular bits.

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Step Up to a Drill Press

While it’s fairly easy to drill most holes in metal using nothing more than a handheld drill, you’ll almost always get greater accuracy and better results using a drill press for metal. It provides unmatched stability and precision. The controlled vertical motion eliminates wobble that often occurs with handheld drilling, resulting in cleaner holes and extended bit life.

When using a drill press for metal, be sure to secure your workpiece with appropriate clamps designed for metalworking applications. Most drill presses are actually built with metalworking in mind. Pulling down on the handle causes the bit to plunge straight down into a workpiece and make a very precise hole.

Drill presses also come with beefy cast-iron tables with tilt and height adjustments and allow a variety of clamping options. Speed changes are as easy as opening the lid and moving a rubber belt from one pulley to another. The most expensive drill presses are floor-standing models, but you can buy a decent benchtop unit for about $200 or slightly less. Consider building a custom drill press table for added functionality.

With these techniques, you’ll know how to drill into metal confidently for any project that comes your way. Remember that investing in the best drill bits for metal will save you time and frustration in the long run and mastering how to prevent overheating while drilling into metal will significantly extend the life of your tools.

FAQs about drilling into metal

What is the best drill bit for metal?

For your average DIY metalworking project involving softer materials like aluminum or basic steel, those standard high-speed steel (HSS) bits in your toolbox will do the job just fine.

However, when you’re tackling tougher materials such as stainless steel or cast iron—or if you plan on drilling numerous holes—it’s worth investing a few extra dollars in cobalt bits.

Many DIYers also find that bits with titanium nitride coating provide noticeably better performance and longevity compared to basic HSS options, potentially lasting up to six times longer before dulling.

Do you need cutting oil when drilling into metal?

For thicker steel pieces (around 1/8 in. or more), using a lubricant is definitely worthwhile. Apply cutting fluid or even multipurpose oil to reduce friction and prevent excessive heat buildup—this simple step makes drilling easier and significantly extends the life of your bits.

When working with more forgiving metals like aluminum or brass, you can typically skip the lubrication without issues. Remember that proper lubrication becomes increasingly important as the size of the hole increases.

How do I prevent my drill bit from overheating?

Heat is the enemy of your drill bits! Keep them cooler by following a few shop-tested techniques: always drill at appropriate slower speeds (especially for harder metals and larger bits), apply cutting fluid liberally when needed, ensure you’re using sharp bits instead of dull ones, maintain steady moderate pressure without forcing the bit through the material and for deeper holes and periodically back the bit out to clear away chips that can trap heat.

Most DIYers find that drilling between 350-1000 RPM for larger bits gives the best results.

What safety precautions should I take when drilling metal?

Always protect your eyes with wrap-around safety glasses—those tiny metal fragments can cause serious injuries.

Protect your hands by wearing durable work gloves, which create an essential barrier between your skin and the dangerous combination of heated metal surfaces and razor-sharp edges that result from drilling operations.

Never attempt to hold metal with one hand while drilling with the other; instead, secure your workpiece with a minimum of two sturdy clamps. After drilling, remember that friction generates significant heat, so allow metal pieces to cool before handling them.

Sources

• Drill bit selection and use:
  • Norseman Drill & Tool: “Feeds & Speeds For Drills”
  • Drill Bits USA: “The Ultimate Guide to Choosing the Best Drill Bits for Metal
• Cutting oils and lubrication:
  • Fusion Chemical: “Selecting the Right Cutting Oil for Drilling Metal”
  • Melkib: “Metal drilling oil 400ml, for machining, milling, sawing, cooling oil, biodegradable”
• Safety and technique:
  • LSU Mechanical & Industrial Engineering: “Drill Press Safety Rules”
• YouTube: “Sharpen Drill Bits on Grinder Fast and Easy”
• House Doctor Home Inspection: “5 Essential Tools for Homeowners”