cutting a hole in metal

[maks8489]

I need to cut a 3 inch hole in the inner fender of an old car I'm working on. The hole will bisect an overlap, where two panels come together and are spot welded, so part of the cut will be double the thickness. Can anybody suggest the best way to go about this? My first thought was a hole saw to get a nice perfect circle, but I don't own any for use on metal, and I don't want to go and buy one if there is a decent alternative.

-Mike

 

[metaleltr]

That is actually probably the cheapest route, unless you have a jig saw, air saw, or air nibblers.

 

[mikeatrpi]

You could also use a saws-all. Cut it a little bit short and use a dremel or file to the final dimensions.

 

[ZRX61]

Masonite template, plasma cutter

Well, ya did ask for the *best way* to do this............

 

[Mike_C]

I had to do this on my 4runner, I first drilled a 1/4" pilot hole then went at it with a hole saw. I also had to buy a 3/8" hex extension for the hole saw to drive it all the way through.

 

[Jack Olsen]

A basic bimetal 3" hole saw will cost you less than ten bucks.

 

[FakeName]

A basic bimetal 3" hole saw will cost you less than ten bucks.

True. That and the $17 arbor for it.

But it's the right tool- we agree.

I had to drill many 3" holes in the stucco soffit of my garage last week. Stripped the teeth off a nice bi-metal hole saw by the second hole.

Nothing that couldn't be fixed with a $50 carbide version.

 

[StumpXJ]

Holesaw. Done.

Depending on where you are, you could likely borrow one from a fellow GJ member. Or cough up the $30 bucks and have your own. If you are in Atlanta, PM me.

 

[trainer]

Layout the hole, jigsaw slightly inside the line, then file/ dremel/ drum sand to the final dimension. Quicker than a trip to the store to buy a hole saw

 

[gorilla]

The right tool for the job is a Greenly chassis punch.

 

[crewchief888]

I need to cut a 3 inch hole in the inner fender of an old car I'm working on.
and I don't want to go and buy one if there is a decent alternative.

-Mike

just think you'll be the envey of all your car buddies,
you'll be the only one with a 3" hole saw

hangin' out in the garage, drinking and benchracin' you whip out your 3 incher





my mind works in warped ways.....

 

[slow50]

unless you hate owning a bunch of tools why not just buy the hole saw? im sure youll use it in the future. and it will cut thin metal just fine. shoot i used a dewalt hole saw to cut through 1/4" steel you just gota know what your doing to avoid breaking teeth off.

 

[Griff93]

If you go the hole saw route, buy a piece of 1/4 in drill rod as well. Drill your pilot hole in your sheet metal with a 1/4 in bit. Take the drill out of the holesaw arbor and put a piece of drill rod in it's place. Now proceed to use the hole saw to cut the hole in your sheet metal. The drill rod won't open up the pilot hole as it turns.

 

[ZRX61]

Lightsaber

 

[racingtadpole]

Lightsaber

Thats what I call my plasma cutter

 

[bad_idea]

Hammer and chisel. Not the cleanest, easiest, or quietest. But it is fun.

 

[Charles (in GA)]

Air hammer and a muffler splitter. you actually get a fairly clean cut.

I would be using a hole saw.

Charles

 

[sberry]

Someone can always find a harder way no matter how much it costs. ha Aint no better way than was suggested, a common holesaw, and if you dont have one you probably need it.

 

[littletoes]

I've hole-sawed literally hundreds of holes in sch 40 pipe with lenox hole saws. The best in the business if you ask me.

Drill your 1/4" pilot hole first, with the saw off of the arbor, then use the hole-saw. You'll have quite a bit less trouble that way, otherwise it could "walk" on you, and tear your rig up.

Think 6" is the biggest size I've ran....we keep a few of each size on hand, but the boss got cheap and bought Morse on the last ones. Lenox seems to be making their's "thinner" these days, but they seem to maybe be better metal, and they incorporate three "steps" that really help getting the slug out.

Good Luck!

 

[Farmrod]

Don't just buy one hole saw buy a set so next time you will have the right size on hand

 

[littletoes]

http://www.lenoxtools.com/Pages/Category.aspx?category=HOLE+SAWS

 

[maks8489]

I ended up using a hole saw like most of you suggested. It turned out fine, though I wish I would have seen this reply before I did it. Good advice there.
Thanks guys.

If you go the hole saw route, buy a piece of 1/4 in drill rod as well. Drill your pilot hole in your sheet metal with a 1/4 in bit. Take the drill out of the holesaw arbor and put a piece of drill rod in it's place. Now proceed to use the hole saw to cut the hole in your sheet metal. The drill rod won't open up the pilot hole as it turns.

 

[SantaAna12]

If you go the hole saw route, buy a piece of 1/4 in drill rod as well. Drill your pilot hole in your sheet metal with a 1/4 in bit. Take the drill out of the holesaw arbor and put a piece of drill rod in it's place. Now proceed to use the hole saw to cut the hole in your sheet metal. The drill rod won't open up the pilot hole as it turns.

thank you.

 

[OccupantRJ]

On larger arbors with the hex shank, the drill bit can be reversed in the hole saw to act as a smooth pilot, as the driving force is on the hex shank.