Metal barn siding…hole saw?

[alex2929]

I am putting up some rusty metal barn siding. I need to cut about 20 - 6.25” holes for lights. Will a hole saw work for this? Is there a better option?

 

[Zeke]

I'm a tool hound. Metal siding is thin and a large hole saw is going to be a handful. Choose carefully. Another option is a nibbler. Make a template and run it around the INSIDE. All nibblers are not equal. Some are very agreeable on corrugated, etc.

 

[jack stand]

A pair of good snips would do it but probably leave you with some blisters. How rusty and what's the profile of the metal? (Wavy, more flat than ridges, etc) a hole saw is going to be "grabby" and a handful.

 

[alex2929]

The metal is rusty but still 95% as sturdy as new. All of the lights will go between the ridges in the flat part of the metal.

 

[Toolfool]

Buy a good bi-metal hole saw.

 

[619DioFan]

Should be no problem since it sounds like you are NOT using standard corrugated panels. if you are concerned about the saw walking cut a template from some scrap lumber with a hole in it slightly bigger than your metal saw to guide it.

 

[NUTTSGT]

I'd probably get a hole saw with a spring made for knock out work. Drill a hole of two and snips. I don't have a nibbler.

 

[Zeke]

The metal is rusty but still 95% as sturdy as new. All of the lights will go between the ridges in the flat part of the metal.

That's good. You can buy a bimetal hole saw for 25 bucks if you aren't going to go into business cutting 6.25" holes. You want to turn that as slow as possible. So if you don't have a big drill motor that can be slowed down with a control, don't do it. It might very well break your arm or wrist. Of course, if you are cutting the holes before the siding is hung, that's a huge benefit. Use the brace hole on the side of the DM for 3/4" pipe and use a long one! If it doesn't have provisions for a long brace, be very wary.

This is not a job for a cordless drill. You can buy a cheap nibbler for under 50 bucks (pneumatic). Much safer and probably just as fast.

 

[csp]

Since they are on the flat I would cut them by hand with aviation snips. There are right and wrong ways to use tin snips as well.

 

[finn]

Seems to me that once the pilot pierced the siding, I ran the hole saw in reverse to keep the teeth from snagging the metal at the bends.

 

[rancherbill]

Screw a piece of backing wood onto the location where you want to drill.

 

[Big Bad Dad]

Since they are on the flat I would cut them by hand with aviation snips. There are right and wrong ways to use tin snips as well.

Yep. I did sheet metal work for several years. I would do this job with red and green snips. Wiss brand was the ones I used. Much better than Malcos, and 300% better than no name chineseum tools....

 

[ycgoat]

A plasma cutter would make quick work of it, and a good excuse to buy one if you don’t already have one

 

[Mzungu]

Even though I have snips, I would use my Milwaukee corded hole hawg with its pipe handle. Nice and slow with minimal pressure. If the metal is not already installed place some scrap lumber underneath to avoid damaging the hole saw or bit.

 

[dcg9381]

I use bi-metal hole saws with a pilot bit. Work great on R panel.

 

[mikedodge]

Use a hole saw. It should be quick. I can't imagine doing 20 holes with a nibbler or snips.
You could always do one and if you're not happy with that way try something else.

 

[alex2929]

ordered a hole saw off amazon. we will see how it works in a few days. Thanks for the replys

 

[dougf]

I had to cut a 2" hole for electric into my shop through metal siding a couple weeks ago. I ended up running the saw in reverse to stop the teeth from ripping the thin sheet metal.

 

[Noltz]

ordered a hole saw off amazon. we will see how it works in a few days. Thanks for the replys

Sorry to drag up an old thread but how'd this work out for you? I have 6 holes to put in ribbed-steel pole barn walls for exterior lighting. Figure I can do steel conduit surface mounted inside the building to the lights easy enough (walls are filled with spray foam), but I want the boxes flush so the lights mount cleanly.