The normal procedure for one or two-off parts is to individually measure and mark each part, center-punch all holes, manually set the x/y coordinates on the drill press table once the part has been clamped in the vise and drill. Follow that by grinding, hole deburring, hand-filing and hand polishing with a ScotchBrite pad. However, that all gets a bit tedious after the first five, twenty or more parts.My solution involved setting up a simple backstop guide on a wooden table that I clamped into my drill press vise. A chunk of walnut and oak that were laying around were clamped in place and a toggle clamp screwed down to hold the work in place.
With the 6061 aluminum being a relatively soft metal, the lack of a center-punched hole did not prove to be a problem. It doesn't hurt either that the designer allows for a generous 1/16" tolerance. Also, close examination of drilled holes shows a slightly triangular shape - evidence of a drill chuck taper/quill runout problem that I need to fix some day. Anyway, this method made pretty quick work of the drilling of the 104 holes (left)
I forget to mention, I used a small flat file after the hole drilling operation to knock off any burrs, allowing the part to sit flat on the grinder table.The next step was to hand-file the burr created by the radius grinding, knock off the burr around the radius and smooth the grind marks a bit.
