RE: Small, broken drills in aluminum...
EDM is what I was trying to think of. That's the one that's very commercil and very expensive.
No real advise on the drills other than buy from a recognized outlet like Enco or similar. Hell, my main set is from the equivalent up here to Grizzly or Harbour Frieght but I try to keep them sharp. I'm still working on ideas for making a drill sharpening jig for drills from 80 up to around 1/4. Sharp drills are the key moreso than brand name I've found.
Sorry Old Git, but for small sizes like we're talking here on this project and in aluminium high speed is what you want to encourage the chips to clear better. But I'll agree on the coolant/cutting fluid recomendation.