Hello everyone.
I just made a new blog on how to cut a perfect hole in glass carbon and kevlar laminates.
The basics is very simple: use the right tool at the right speed.
A few more tips are available like using a softer material under the part to drill, vacuuming the part as the drill progresses, letting the part cool down to avoid heat buildup.
Note that these laminates do not like too much lubrication during the drilling progress.

Here is a picture of the tools I am using:



These are by far the best jobbers I have ever used and 100% made in the USA.

A link to the blog:

http://www.ultimate-jets.net/blogs/j...vlar-laminates

And to the cutting video tutorial with a column drill:

http://vimeo.com/69224557

And with a hand drill:

https://vimeo.com/69224557

Also for cutting a conical recess for countersink screws, I use some 6 flute carbide cutters:



I've got two sizes.
The small one has a 1/4" flute is particularly adapted to super scale embedding of micro countersunk screws.
I also use it to machine offset hinges securing screw recess, and for scale panel access fasteners.

The other size is 1/2" flute and is very handy for bigger countersunk screws like nylon screws, retract fasteners that need to be flush, or any other heavier duty job.

Both tools are USA designed and made titanium oxide coated carbide cutters.
http://www.ultimate-jets.net/collect...de-countersink

Here is a video showing the use of the 1/4" flute countersink on the Scorpion Mk2 fuselage:

https://vimeo.com/69360377