Quote Originally Posted by buffalobo View Post
Not a simple or easy way to use drill bit to make a countersink in washer. Almost impossible to "hold" washer while being drilled by hand or on drill press.

I have made aluminum washers by drawing them on 1/8"(x whatever width you need to get washer size) thick material, use counter sink bit to make center hole and bevel, then use hole saw to cut out washer.
Believe it or not, holding the washer isn't the problem. I have an attachment on my press that holds it perfectly still, but the drill bits barely make a dent, and I'm ruining drill bits. Also tried to use a countersink, which didn't work (not surprisingly, since they are intended for wood). I've drilled through much thicker metal with this press, which is why I'm flummoxed by the washers...