Have to use a hole saw!?!?
The brad point bits I ordered won't work?
I've never seen a 3"deep hole saw, or a 3/8" hole saw of any depth.

I got my drill guides made yesterday. Went to the local metal sales outlet.
They have scrap area of cut-offs. Found some 3" by 4" pieces of 6061
that were a little over 1" thick. Tried to pay them but they just said take'm..
Brought them home and broke in the new drill press. Next challenge,,finding exactly where to drill on the transom.

I think he meant for the 1 inch holes a hole saw would be better. and I go half way thru transom and run pilot hole all the way through. then continue from other side to complete hole.

Ok, I can see that working, however, I'm not sure if I will have good access from the bilge side.

Try to get into the bilge to finish the holes. If you can only drill from one side you will get "blow out" and it won't look as nice.

Ken

If you can't finish the hole from the bilge side, go real slow for the last 1/4" and the cut can be clean if you are careful.

I was asking on another thread abt using a pilot hole with brad point drill bits. Never got a reply on that. Seems like the bit might try to dance around. Maybe if it was a really small pilot hole??