I have had great results drilling UHMWPE with wood workers Forstner bits.
Just as with wood, these bits cut holes with very straight, smooth sides in
UHMWPE. OTOH, metal twist drills tend to push material aside which then
rebounds to make the hole smaller than the nominal size of the drill. I
replaced the nylon pushrod fairleads in my sailplane with UHMWPE using
Forstner bits to drill the holes slightly bigger than the pushrod OD.

Bill Daniels

"DonMorrisey" wrote in message
oups.com...

To OP: was there a +/- type of allowable clearance given, as a
recommended
range?


Jim, it was suggested that I oversize the hole by .002. There is great
information in this post and I thank everyone for contributing.

Don.