Brief Description: Up-drill front fork attachment holes
The other day I pilot-drilled just the nose strut. Six 1/4" bolts are required, so I clamped the strut to the nose fork and reinforcement securely, then started drilling.
First holes were from the topside of the strut into the aluminum since there were no pilot holes there. All subsequent holes were drilled up from the aluminum fork up to the nose strut since there was more room for the drill. Went from #40 to #30, then #20, then #12, then 1/4'. Used oil to keep the drill cool and prolong the bit life.
Since I didn't have any 1/4" clecos, I would up-drill a #12 (3/16") hole one at a time and put an AN4 bolt in it. I used 4 washers and a nut; the washers used to keep the bolt from ruining the nylock part of the nut.
Once all 6 holes were up to 1/4" size, I then drilled the 4 AN3 bolt holes from the main fork to the inner doubler.
one hole at a time up to 1/4"
Up drilling strut to 1/4"
strut to fork drilled / fork reinforcement drilled