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 LS: Yes #80 is about as small as it gets, .0135 inches, or about 4 sheets of typing paper in thickness. If you don't have a template I suggest you use a model drill press with as short a drill as you can get into the chuck. The idea is to have a very short shank to flex and break the drill. Failing that I would use a "finger vise" again with a short shank. This is the less accurate and uniform way to do your work. I suggest you also use a large needle to "center punch" your work, even if pre-registered on the model. Use a pin vise as a holder. The idea is to give your drill a place to bite into the plastic. I wouldn't use a power tool, it is apt to create too much friction heat and either melt or bind the drill. Others may think differently. Final hint: BE VERY VERY PATIENT. 70 holes is a large number to drill out in registration. Good Luck Randy
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