DRUMMER CAFE

Anybody have any suggestions on proper drilling techniques & bits for drilling Vistalite (Plexiglas) shells?   I have a lead on an old 70's Vistalite marching bass drum that I'd like to convert for drum set use, so I'll need to drill the shell for the spurs.

Do not use a sharp bit!  Use the dullest bit you own.  The sharp bit will dig in and crack the plexiglass.  Aircraft mechanics will dull a new bit to drill holes on concrete before trying to drill plastics.  Putting a new bit against the concrete floor and letting turn a few times will remove the sharp edge and make it perfect to drill plexiglass. A slow speed will also help.  Stop by the hardware store and buy a small piece for practice. 

I would suggest to drill slowly, or drill a small distance, and back out, let it cool.  That stuff can get hot and melt.  I don't know if it will get hot enough just drilling through a drumshell, but one can never be too careful.

When I drilled vistalites I had two problems:

Small drills would heat up the material, get stuck and not want to come out- it happens really fast too.  So maybe try to use a slower drill speed and keep your bit clean.  I wish I knew of a good drilling lube for plastics... maybe a PTFE or silicone based lube?  Try it is all I can say.

Breakthru-  very gnarly with this stuff.  Without a drill press to keep the bit from sucking thru the material wants to break/chip leaving a pretty big looking gouges on the breakthru side.

You could maybe drill part of the way thru, get an endmill, lock the head and then dial up slowly with the knee handle (if you are using a bridgeport type mill).

There is really no easy way I know of.  Hell I just went for it with a cordless drill and was careful.  It worked; not pretty, but worked.

Update:

I picked up the green Vistalite bass drum last week.  It's a 14x24.  In its previous life, it was a marching bass drum for the CYO Youth Band of Chicago (Jr High-aged kids).  Consequently the drum looks a bit like it has been ridden hard and put away wet. 

The wood hoops will need to be repainted or replaced.  There's a lug/claw missing.  Nevertheless, there are no major scratches on it and the shell is in good shape. 

I plan to use this drum as the foundation of a Jellybean Vistalite set.  Next on the radar are a 8x12 or 9x13 rack tom in yellow, and a 14x14 floor tom in blue or amber.

I'll order the missing Classic lug & claw from Ludwig, and pick up a pair of spurs.  I'm leaning toward the newer style of spurs instead of the "period correct" retractable curved spurs (the newer style requires less drilling into the shell and smaller holes).

I'll put up some photos when I start working on it.