I know many lugged frames start with pre-drilled lugs to create accent spots to be filled with contrasting paint later. Was wondering if it was possible to replicate the effect on a already assembled frame using a drill press or other device. Reason being to save money but add a bit of customization.
Have access to the drill press here at school and would only be doing it to lugs where i could adequately brace the frame to align the holes (probably along the tops or bottoms of lugs, nothing inside the triangle). Would attempt to drill only through the lug, perhaps not even all the way through that. Some slight research led me to cobalt drill bits for using on metals. Would i need to find something special to make the hole more flat on the bottom or should i be content with a convex bottom?
Frame in question is the alien steel lugged frame http://www.alienbikes.com/gear.html. If i were to purchase it with a powdercoat would i need to worry about rust even if the holes were filled with paint?
Last question first, I wouldn't breach the powdercoat myself it can peel, obviously this should never happen, but what you are proposing would involve heat and or oil, so all bets are off.
You can use a mill to get in there and probably some kind of engraving rig. I wouldn't do it, the titanic mess up god would be looking over your shoulder. What if you get in there and find that the braze is uneved, and you have a gap between the lug and the tube, I'm not even thinking of structure, just a bubble, isn't going to be easy to heal. I;m no lug sculptor but I figure there has to be some better way to customize a bike.
Standard HSS is the best. Easy to sharpen wicked shapr and lasts well when run with proper speed an lubrication. A lot of better cutters are designed for modern work where there is flood collant etc... Of for weird materials.