Quote:
Originally posted by #Rotor
JD, how is this for an idea. pre drill the holes such that when you go with the final sqr-end bit, that it's diameter is such that each hole just barely cuts into one another.
the only reason this is not possible with a drill-press and normal drill-bits, is the fact that the bits are so bendy and braky.. 
this will give the formed pins the perfect shape. the Sqr-end bit will also not be so prone to wander, as it will be cutting on the perpendicular plane to the downward force applied.
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I was of the understanding (mistakenly?) that this would result in pins being too small - copper/water ratio being all wrong. No?
Bob