I need to drill 200 - 400 holes in a solid from 2 different directions. One hole is a #78 bit (0.016") and the other is a 0.125" diameter hole. The 0.016" hole is 0.050" deep and the other hole is drilled from the other side to meet with it. It's easy once but I need to do this a lot of times in a part. Example:
These holes need to be in locations similar to this:
What I have tried:
Hole wizard: The small hole works fine but the large hole runs into problems when setting positions. I end up having to set positions without constraining the large hole to the small hole and then going back, editing the large hole position sketch and setting relationships between the 3Dsketch of the small hole to the large hole. Time consuming!
Revolve/Sketch driven pattern: Creating a revolve that is the shape of the large and small hole together. After the revolve is finished I do a sketch driven pattern to make holes in the proper locations. This works better except that sometimes holes overlap. When that happens I have to go back and edit the sketch for the locations and then make some sort of new hole that is large for the overlapping holes. Again, better than the Hole Wizard method but still time consuming.
Hole Series: This doesn't seem to work because it is a solid rather than an assembly with multiple components. Other than that it seems like it could be a possibility.
The ideal solutions would use one sketch for the position of the holes, create the hole series with one command and the replicate the holes quickly without creating overlapping holes that cannot be drilled.
Does anybody have any suggestions so I could spend less of my time doing tedious holes and more time designing?