I riveted most of my remaining aluminum in place as I hope to spray Lizard Skin soon. Before I put the rear cockpit wall in place I figured I better get my Breeze roll bars drilled first or else it would be nearly impossible to get in position to drill the holes. I read that a lot of people struggled with this but I didn't find it too difficult so will detail what I did here.

From looking at how I could drill from two sides, and to gain access to the roll bars once the body is in place, I decided to drill the holes in a mostly front to rear orientation. I bought three drill sizes: 1/8", 1/4", and 7/16". I bought the Milwaukee cobalt drill bits at Home Depot. I bought 2 of the 1/8" bits and one each of the others.



I'm lucky to have access to a large drill press with a cross vise and it definitely made the job easier. I center punched the tubes at each leg and drilled with the 1/8" bit first, then the 1/4", and then the 7/16". I would swap out the bits and completely drill each leg to completion before moving to the next leg. I ran the press at 550 RPM and used lots of Tap Magic oil. It probably took me just over an hour to get them all drilled.







I then honed out the inside of each leg a bit with a drum sander bit on my cordless drill to remove any burrs and greased up the inside of the legs and the stub tubes. The roll bars pressed back onto the stub tubes fairly easily. I aligned them to the top of the paint marks I had made earlier which are 3" above the floor of the trunk. I then used my center punch to mark the center of each hole on both sides.



Using the same bits as before I drilled 1/8" pilot holes on each side. I did NOT try to drill through to the other side as I figured it would be next to impossible to get the holes to line up that way. I then moved up to the 1/4" bit and finally the 7/16" bit. My cordless drill was struggling a bit on the 7/16" bit, probably because it was getting pretty dull a this point. I switched to my corded 1/2" drill to finish these up. Here is the final product, all six legs and rear stub tube drilled and with through bolts installed. I am glad I decided to plug weld the front stub tubes in place as that saved me from having to mess with an additional 4 holes. I have read that some think it is a bad idea to weld them in place as they needed the additional movement in order to fit the bars, but I don't think that is the case, at least I didn't have any problems at all with the way I did it here. All told it was probably about a total of 2.5 hrs to complete this job.