Hi zsadecki
You need:
1) a high speed drill, the higher the better.
2) you need something convenient to use. i.e. light and small since you are going to drill a lot of holes
A quick lesson in theory:
The ideal RPM cutting speed formula used by machine shops is:
RPM ~= 4 x Cutting Speed [ft/min] / Diameter [in]
where Cutting Speed for Aluminium is +/- 250 ft/min
Using this 'ideal cutting speed' formula you'll see that:
For our
#40 (3/32") skin holes the ideal RPM speed is:
RPM = 4 x (250) / (3/32) which =
10,666 RPM
and for our
#30 (1/8") holes the ideal RPM speed is:
RPM = 4 x (250) / (1/8) which =
8,000 RPM
Luckily we drill through thin material so we can get away with lower speeds.
The slower the drill speed the more the metal deforms
Back to reaility:
Air drills:
The GOOD air drills sold by the aircraft tool companies turn about 3,600 RPM and weigh 1.5lb and 6" long and has a variable speed on it (the Sioux make for instance). The problem is the air drills consume a lot of air hence the compressor kicks in often, in addition the air pipe can be heavy! It is also very noisy.
Electric drills:
Generally Electric drills typical do not turn that fast, and can be a bit bulky to use. But they are quiet and do not have a heavy pipe to cary around.
The best one I have found and they guys use here is the
Matika 6501.
This drill turns at 4500RPM which is very good, (better than most airdrills) and weighs in at 2lbs, it is small and compact 8", not so noisy and do not have the heavy air pipe. The only problem is it is not a variable speed. So one have to use another 'variable speed' or low drill speed drill for the bigger/thicker holes and steel holes.
If they made a high speed (3,600 RPM+) electric drill in variable speed and in a compact form, maybe even cordless...then that would be you're ideal choice! I have not managed to find one yet...
Hope this helps,
Regards
Rudi