I want to open up a 3" hole in the H-D center caps similar to the opening in the stock center caps used on 4WD SD and Excursions. This hole is only for the purpose of having access to the OEM hubs. While I could very easily pop off the center caps for access (as mentioned by @brookieslayer), at some point the OEM hub(s) will go awry and I'll migrate to a manually locking unit.

Originally my idea was to place the center cap on the lathe and use a cutting tool at the desired size.

A friend made the suggestion that using a hole saw would be more appropriate, just have to make certain that I find center otherwise I'd have an off-center-wobbly-wormhole looking thing.

Please feel free to offer any other/alternative ideas for consideration.

TIA

 

HELL NO! Just pop the caps off lazyass lol

 

The caps don't pop off that easily. I cracked one taking it off and to replace was not cheap (for what it is).

 

I would go with your original idea and use the lathe.

 

The only way to make sure it would be perfect is to use a lathe and put the 1/4" hole in the cap. Then a holesaw could be used to make the hole, another option would be to make a jig that fits the inside of the cap and have a pilot hole in the middle to perfectly centre the 1/4 inch hole for the hole saw. The latter could even be made of wood.

 

I'm with you! Keeps it nice and clean, once I lock mine they will remain locked until next year so maybe its not such a problem for me.

 

Sorry to interrupt, but this seems a perfect time to ask a pertinent question. What is the preferred way to take off those center hubcaps?

 

The tool that comes with the truck with the little rubber tip

 

D'oh!

h/t to Homer

 

So, I put a center hole into the caps of my aftermarket wheels. The center caps were held on with allen screws, so there was no quick way to get to the hubs, plus the caps were too short to clear the hubs.... What I ended up buying was a hole saw that was as close to the size of the hub that I could find. then it was a simple matter of marking center, drilling an initial small guide hole, then slowly, and I mean slowly using the hole saw to eat its way through the cap. it works fairly well overall.

 

 

Mark- Hole-Saw is the way to go, but, Pro-Tip: After finding & drilling center, first run the hole-saw in reverse before cutting in correct direction....makes for a much cleaner cut.

 

I can see that given the chrome-esque plating finish.

The edges (of the opening) has been one of my concerns, hence; asking for ideas, much appreciated.

 

I used a hole saw on my aftermarket center caps. I lucked out as there was a small nub dead nuts in the center on the inside of the cap leftover from the molding process. I drilled an eighth inch hole fron the inside out, then used a hole saw from the outside. Came out nice. If you don't have a mark in the center, I'd just measure and mark from the outside. I think as long as you end up very close to the center..... no one is ever going to notice it's a few thousanths off..... not even you. Especially when the truck is rolling down the road.

 

Mark - can you post a picture when you finish?