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I would assume the holes are the same as an MHSv1 heatsing since they are designed to match the notches in the LED module.
Holes are 1/8" and on a /75" circle o an MHSv1.

The 12mm AV switch I bought from TCCS has an M12x.75 thread.
If you plan on taping the hole you want an 11.25mm drill ( took some time to find a chart with that size/ thread pitch)
a 7/16 may...

Is it a cordless drill/ driver with an adjustable torque for driving screws?

Mine has trouble drilling if I forget to reset after using it for screws.

There are several companies that sell SW Blaster parts online and ebay.

Check the RPF forums, I think I got several good links there.

check this thread
http://forums.thecustomsabershop.com/showthread.php?19545-Drill-and-Counter-sink-Tutorials

Even if you can machine parts yourself it is probably more economical to use the blank MHS parts as often as you can. The cost of materials, time boring out the inside and threading are about even...

Drilling into thin walled tubing is difficult because the bit will bite then clear as it rotates causing the bit to chatter.

Some basic pointers:
Use a drill press.
Use a vise with a notched...

If I understand the problem the nuts extend past the edge of the chasis.

Could you glue the nuts in place at that end and file off the part that sticks out?
Do the flats (of the nut) extend past...

There are three major problems with drilling into the threads.
1) You may produce burs between the threads that make it difficult to disassembly without damage.
2) You are drilling into curve outer...

Local is almost always better since shipping anything metal over a few inches long get's expensive.

Metals Supermarket has a fair number of locations.

Online retailers prices vary by product, I...

I feel your pain on shipping for raw material.

I think the moderator misunderstood your question but give him credit for the way he replied.

I assume you are working on an advanced sink tube...