How to make a hole?
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Senior User
Joined: Jun 2003
Posts: 285
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From: Kannapolis NC
How to make a hole?
Is there a simple way to make 2" to 2 1/2" hole in sheet metal? say 16 guage? or does it require grinding away with a hand grinder? Any special tool for this job?
FTE Legend
Joined: Oct 2005
Posts: 283,683
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From: northwestern Ontario
I would suggest a hole sawor if you know someone in the electrical field they may have access to a greenly which cuts a hole by pulling a cutter into a cup, requires you to start with a smaller hole for a bolt and just tighten the to pieces together,makes a very neat hole. Hope this is of some help.
Cargo Master
Joined: Feb 2008
Posts: 2,795
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From: Windermere Valley,B.C. Ca
My turn, my turn, pick me!! 
Air nibbler? Jig saw with metal cutting blade,
Air nibbler? Jig saw with metal cutting blade,
Last edited by Old F1; May 1, 2009 at 07:17 PM. Reason: oldtimers
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Cargo Master
Joined: Aug 2008
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Likes: 23
cutting torch.
Hole saw will work well too, just don't use your good one as it will dull it a little.
You'll want to punch the dead center before you drill your pilot hole, otherwise it WILL move on you.
Don't forget cutting fluid if you plan on doing more than one, too much heat will ruin the heat treat on the bit.
Also, having a wood backing will be a good idea all the while (unless using a torch of course!) It will keep the drill from pushing rather than drilling.
Hole saw will work well too, just don't use your good one as it will dull it a little.
You'll want to punch the dead center before you drill your pilot hole, otherwise it WILL move on you.
Don't forget cutting fluid if you plan on doing more than one, too much heat will ruin the heat treat on the bit.
Also, having a wood backing will be a good idea all the while (unless using a torch of course!) It will keep the drill from pushing rather than drilling.
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Brett Foote
FTE Legend
Joined: Oct 2005
Posts: 283,683
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From: northwestern Ontario
I think that the air nibbler is a good idea but would also recommend that you make a guide to follow unless you have a very steady hand.
John
John
Laughing Gas
Joined: Jan 2009
Posts: 914
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From: Lavergne, Tn.
All the hole saws that I have ever used have the pilot bit in the fixture that the hole saw mounts to.
The orange hole saw in the picture has a 1/4" bit that is not visible in the picture. I used this saw to cut the 4 holes in my roll pan for the sunken tail light housings. Little tricky since the pan is curved.
I've got Greenlee punches but they require drilling a 3/4" hole for the bolt on the punch to go through. Not as convenient to use for me.
Any Lowes or Home Depot will carry a variety of hole saws.
Andrew
The orange hole saw in the picture has a 1/4" bit that is not visible in the picture. I used this saw to cut the 4 holes in my roll pan for the sunken tail light housings. Little tricky since the pan is curved.
I've got Greenlee punches but they require drilling a 3/4" hole for the bolt on the punch to go through. Not as convenient to use for me.
Any Lowes or Home Depot will carry a variety of hole saws.
Andrew
Senior User
Joined: Apr 2009
Posts: 377
Likes: 2
From: Ashland, KY
come to my house, i'll cut it with the ol trusty plasma gun, lol.
if you use a "drill" type cutting tool, i've had good luck with '3 in 1' oil as a lub.
you should try going to a larger junk yard, most of those guys have a CnC plasma laying around, i bet they would cut it for you.
if you use a "drill" type cutting tool, i've had good luck with '3 in 1' oil as a lub.
you should try going to a larger junk yard, most of those guys have a CnC plasma laying around, i bet they would cut it for you.
Senior User
Joined: Feb 2006
Posts: 100
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From: rochester n.y.
holesaws
As a retired elect. I rave drilled or punched many holes in all types of material. conduit punches are labled by pipe size not cutter size,measure cutter for exact size.most hole saws use a 1/4 in. pilot bit,after I drill the pilot hole, I reverse the drill bit in the mandrel,or use 1/4 in.round stock for a pilot,in soft stock such as aluminum or wood the drill bit may enlarge the pilot hole.
Hotshot
Joined: Nov 2000
Posts: 11,591
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From: Pflugerville, tx
As a retired elect. I rave drilled or punched many holes in all types of material. conduit punches are labled by pipe size not cutter size,measure cutter for exact size.most hole saws use a 1/4 in. pilot bit,after I drill the pilot hole, I reverse the drill bit in the mandrel,or use 1/4 in.round stock for a pilot,in soft stock such as aluminum or wood the drill bit may enlarge the pilot hole.
Sam
