Drilling in a tight place

[Brad_bb]

So I have a narrow cabinet door and I need to install a ball catch from Rockler.  


 
The door is no problem, but the catch in the frame of he cabinet is a tight space to bore a 7/16" hole for the catch.  I have the Dewalt right angle, attachment, but I cannot find a stubby 7/16" brad point drill bit.  


 

Between the front of this right angle attachment and the wood I need to drill is about 3.75".  How can I bore a 7/16" hole in this space?  Is there anyplace with a stubby 7/16" bit that is hex drive?

[DMcCoy]

Have you looked at McMaster Carr? 
You might have to make one.
You could use a lathe center drill, cut one end off and hot glue into a 7/16" socket.
If you have access to a milling machine I have made straight single flute drill bits from grade 5 bolts.  You might be able to grind one as well.  Again hot glue into a socket

[21incher]

I have cut down a cheap spade drill bit for a tight space. Once you get over 3/8 it seems like you would have to make it. A forstner bit could probably be cut way down with a soft enough  shank to drill and braze in a hex drive bit. milwaukee bits have a round small shank that could probably be brazed in any stub of a cheap low carbon bit that can be easily  drilled. A simple guide block could be used to locate it.   

[21incher]

Just grabbed some stuff I would  use. A forster bit and short hex socket.
Cut the bit at the tape with my cutoff wheel. Then either  grind some flats to fit a smaller socket or for just one hole jb weld the bit in place after roughing up the shank.


 

 
That can get to a 3 inch total with about 3/4 depth.

[Brad_bb]

Thanks guys.  @21incher that looks like a plan.  I have about 5 inches total spacing for the right angle and bit.  So I just need to find a socket bit like that... and get the good concentric fit putting them together, so that the Forstner bit spins true. If the shank is bigger than the socket, Maybe I can spin the bit in a drill up against my bench grinder wheel?

[21incher]

With 5 inches you could just use a rt angle  drill


 
Another  option if you can go deeper is a step drill with a piece to prevent  tear out clamped to the frame


 
Amazon has many hex shank shorties that are still twist drills but a piece  to prevent  tear out should keep the hole clean also. An extra inch opens up the options.

[Brad_bb]

I've got to get the forstner bit so that I know the dia of the shank where I'll cut it off.  I need to measure that and make sure it will fit one of the Compact hex sockets I found from Dewalt.

[SwampDonkey]

Festool makes hex shank with that diameter bit. Their stubbies are metric and no 11 mm, just 3-8 mm.

Festool Brad-Point Drill Bits - Lee Valley Tools

[Tom King]

https://www.amazon.com/NordWolf-Cobalt-Stubby-Stainless-Drivers/dp/B0C23KK4TY/ref=sr_1_2_sspa?hvadid=594988259183&hvdev=c&hvlocphy=9009786&hvnetw=g&hvqmt=b&hvrand=4976486256607957237&hvtargid=kwd-1651774426306&hydadcr=28594_10166490&keywords=short%2B7%2F16%2Bdrill%2Bbit&qid=1701870837&sr=8-2-spons&sp_csd=d2lkZ2V0TmFtZT1zcF9hdGY&th=1

[Brad_bb]

@SwampDonkey  You don't have any of those Festool bits to be able to measure how long they are do you?  I've sent a message to Festoolusa cust service, but I have no confidence that they will provide me the length.  Past experience says they will be no more helpful than Chesticles on a bull.

@Tom King  I did see those, but I'm not that confident that they will stay centered in oak. If I tried it, I'd try drilling a little pilot hole in hopes it would follow it.  The cut may be pretty rough too given the shape.  They advised uses are for hard metals, not wood.

[SwampDonkey]

Just sent Lee valley a request for length of the 7/16" diameter bit end, excluding the shaft length. So probably get a straight answer soon.  I know different sizes are different lengths like regular bits are.

[Tom King]

I think if you made a little wooden guide block for it that clamps to the rail it would do fine with a slow feed and also prevent blowout at the surface. 

[SwampDonkey]

Frank , at Lee Valley, said they don't have any bits at their stores in stock to measure and Festool doesn't provide the info at their website. A lot of stock, most, are shipped out of their warehouses. I'll be able to tell you in a few days as I have a set I ordered this morning on the way.

[mudfarmer]

Sounds like you are on track but in case it helps someone else in the future, I got some tools to do exhaust manifold studs on one of my trucks, and the company sells a drill chuck that goes on a 1/4" drive air/electric ratchet. This apparently gives an even smaller package than a bit in a right angle drill? The company is ProMaxx

[Brad_bb]

Festool actually got back to me via email and said the 7/16 bit is 4.5".  It would be real close.  I need to go measure again with the right angle attachment.

@mudfarmer  I'll look for that Promaxx.

[SwampDonkey]

As for the 7/16 bit, the overall bit length is 4.5" long to the point tip. But the hex shank is 5/8" long, then another 5/8" down to the shoulder that is round with 1/4" diameter, then another 1/8" before you hit the flutes of the bit past the shoulder.