Heavy drillin

To drill a 1-inch hole in 1-inch thick steel without stalling, you’ll need a drill press with more torque or a lower speed setting. Upgrading to a stronger motor or using a carbide bit could also help.
 
When I need a hole that is bigger than what I can drill, I use a shaft/set collar if possible.

If it can be welded to the mother steel. Sometimes just torch out the desired hole a bit too big and weld the set collar over in the right spot.
Or if needed torch the hole out so I can recess the setcollar flush with the mother steel and weld it in place.
 
No- a Bridgeport is not overkill and neither is this. Here's a 1" drill in my Bridgeport killer. Set speed and feed, turn on flood coolant (not oil), hit start and let it eat.

Dan

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All that swarf looks similar to my pile, around my Millrite. The Millrite is good for a smaller shop, with limited space. About 2/3 Bridgeport size.
 
Bridgeports, etc are great for a LOT of things but for simplicity and speed it's still tough to beat a gear head drill press.
Drill press is mostly limited to drilling and tapping holes but boy oh boy they do those two things well.
 
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