Cutting 60mm Hole in Plastic

[PCustoms]

12 gauge @ 10.375”

What load?

3.5" turkey, 2.5" target, slugs etc

 

[steel 35]

Move back as needed;
or adjustable choke

 

[wssix99]

Easy fellas. It's just a dashboard - thin plastic.

I am working on a car project were I need to cut a precise 60mm hole in a piece of plastic dashboard material.

Don't scare off our new member by turning this in to the Manhattan Project! (If its too complicated or tight, one can get a step drill that maxes out at 60mm. No fuss, no grief, no worry about over-reaming.

 

[The Cobbler]

Don't scare off our new member

He's been around a while. just saying.

 

[PossumDog]

I have used an expansive bit in a hand held brace. Can set the radius to exactly what you want and rotate as slow as you want.

 

[Spareparts]

If you are using a hole saw drill the pilot hole, change the drillbit out for a 1/4" rod or the drillbit is going to eat
the pilot hole out as soon as the holesaw hits that plastic.

 

[rharman]

Hole saw in reverse, Forstner, or a step drill - all previously mentioned.

Forstner was my first thought - I didn't think about a step drill that large.
Would probably be great if you have the depth behind the face to handle it.

 

[jonesg]

Happy New Year guys. I am working on a car project were I need to cut a precise 60mm hole in a piece of plastic dashboard material. I am stuggling to find a hole saw blade that is not coarse or made for wood or metal. Any thoughts on how I could do this. Thank you!

it can't be done, get rid of the car.

 

[Youngandfree]

What load?

3.5" turkey, 2.5" target, slugs etc

Federal Flight Control 8shot buck keeps the pellets within the A-zone at 25 yards.

 

[Citation]

Did anyone mention knock out punches yet?

 

[cgrutt]

I like the step-drill suggestion and would try that if it works. Back in the day we cut many precise (to the eye) shapes in plastic dashs with dremels w/ carbide bits and files but it takes a lot of practice to get good at it. Helped if dremel was variable speed and adjusted to cut cleanly as some plastics had a tendency to melt back together and build up a burr. Direction of cut will alter which side of line the burr forms on but very easy for the carbide bit to climb over cut line. Wouldn't recommend this as first choice if you can get a precise and clean cut with a bit or hole saw. We tended to use dremel and file for irregular shapes for example fitting a rectangular shaped radar detector flush with dash etc.

 

[CraigStu]

I know we are coming off a holiday but the OP hasn't been back in 52 posts.

 

[niget2002]

I know we are coming off a holiday but the OP hasn't been back in 52 posts.

Hopefully he has the hole cut by now.

 

[Pexto]

They are pretty useless otherwise, but an adjustable bit in a brace works really well for situations like this in thin plastic or soft metal. The cut is very controllable and you can dial in *exactly* the size hole you need.

Edit: Sorry, I missed PossomDog's post suggesting the same thing first.

 

[WILD-BILL]

I'l use an M 203 personally.

 

[rayra]

Man you guys could complicate anything. A 60mm bimetal hole saw for wood will work just fine. In either direction. Particularly if you are looking to put a gauge hole thru a piece of plastic sheet suitable for an instrument panel.

 

[PugetDude]

I have a 60mm TCT Hole Saw that would be perfect for this job. Pilot bit to keep it centered, nice and slow, short bursts in a cordless drill.

 

[Captain Spaulding]

60mm OD pipe and tube is available. Sharpen by grinding a bevel on the inside. Hammer through. If you can tolerate a little goo, heat the pipe And push it through.