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Don't drill an undersized hole. Drill the proper size hole. Sizes are noted above. This. I use these. Again, I'm not being argumentative, but I think some of your advice is a little off base.

That's looks great - nice work.

Perforated vinyl is pretty much the industry standard.

Not that I've heard of. Electrical sign installers use rotary hammers all of the time on brick and that's drilling larger holes for PK housings, etc.

Well, quick update on this. I came across this comparison which is exactly what I was looking for: click Given the wide range of specs, they didn't pan out the way I thought they would which makes me think there's some research behind these rather than just producing a tool with the highest...

That Bulldog gets nothing but good reviews. Just to be clear, I wasn't comparing hammer drills to rotary hammers. I was comparing the various cordless rotary hammers. I think you forgot the picture. :)

Clarke Systems, Slatz

I was referring to their epoxy (as stated)... Not their glue. I mistakenly called the brand name Gorilla Glue rather than Gorilla. Sorry for the typo. Obviously a simple glue isn't the solution.

You might try a 1 or 3 minute epoxy or Gorilla Glue epoxy.

Any reason you can't stud-mount them?

Weld-On 16 Specs: Bonds rigid PVC, ABS, styrene, butyrate, polycarbonate to themselves and each other, as well as other plastics and porous surfaces. Maybe that backer isn't one of those materials. Maybe there's chlorine or something in the water or embedded into the backer that's not allowing...

I've never specifically asked any manufacturers/vendors that question, but I'm sure the primary reasons include: - aluminum is soft and can be cut quickly and easily on a router - aluminum is easier to drill and tap for stud-mounting - aluminum doesn't rust - aluminum is much lighter...

Steel isn't used nearly as much as aluminum. When steel is used, it's typically stainless.

Even with polycarbonate, he should be ok if using Weld-On 16 though. Weld-On 3 should only be used on like-materials (acrylic with acrylic, polycarbonate with polycarbonte, etc.) Weld-On 16 can be used on unlike materials (acrylic with polycarbonate, etc.). The Gemini pads (not sure if that's...

If both pieces are acrylic, there's no reason it shouldn't hold. Sounds like you probably already know this, but the Weld-On cement acts the same as PVC cement in that it actually chemically welds/melts the two surfaces together. So the cemented part will typically become stronger than the rest...

What's a "cord"? :Big Laugh That's the beauty of a lot of the new cordless stuff - their performance is comparable to the corded stuff. More money out of pocket, but no generator or extension cord to carry around. I keep a Bosch 5/32" SDS bit in the truck. Got it from Home Depot and use it for...

Those are cast aluminum. I would have Gemini handle it. And yes, you would need a pattern.

Yeah, not counting Hilti, Bosch has been to hammer drills & rotary hammers what Milwaukee has been to the reciprocating saw. Everyone is raising their game though. In the cordless versions I listed, Hilti is the heaviest but has lower specs than others. Yet it costs twice as much. Great service...

For stuff like that, I won't have anything thinner than .125" welded. Lord's works great and there's no risk of warping. I would hope Gemini puts a rush on the replacement letters. Nothing like having to explain stuff like that to the customer.

I'm having to install the letters shown in the attached photo to the stone-faced monuments. Each letter has 3 or 4 studs, so I have to drill a 3/16" hole for each stud. There are 6 sets of these letters altogether, so when drilling that many holes, my mind always wanders to whether or not I'm...