Profile Posted February 15, 2016 Report Share Posted February 15, 2016 Ever try to cut a hole in say a dash board with a hole saw, The hole will look like s@%# because of all the chatter from the saw. Easy fix and you'll end up with perfect holes ever time. All you need is a spray bottle of water and a board to clamp the aluminum down to. Run your drill press on the slowest speed that it'll go and as you bring the hole saw down to touch the aluminum, spray water on the aluminum for the entire time you cut the hole. Why this works I doin't know, but you will end up with a perfect no burs, no chatter hole. 3 Quote Link to comment
Mattndew76 Posted February 15, 2016 Report Share Posted February 15, 2016 WD-40 works better. Why it works is because you made the aluminum more rigid. You clamped it down to a board. Vibration and inadequate holding causes chatter. Always secure your aluminum plates to a more rigid object for better finishes. 2 Quote Link to comment
Z23T Posted February 16, 2016 Report Share Posted February 16, 2016 http://www.eaavideo.org/video.aspx?v=3617603499001 EAA video, they are into home built aircraft, showing how to use a fly cutter to cut large round holes in aluminum. There are lot's of other cool videos here as well. Cam. 2 Quote Link to comment
thisismatt Posted February 17, 2016 Report Share Posted February 17, 2016 http://www.eaavideo.org/video.aspx?v=3617603499001 EAA video, they are into home built aircraft, showing how to use a fly cutter to cut large round holes in aluminum. There are lot's of other cool videos here as well. Cam. Wow, that was painful Quote Link to comment
Z23T Posted February 17, 2016 Report Share Posted February 17, 2016 Wow, that was painful Yeah, some of those videos drag on and on, but there is some good info in there. Cam. Quote Link to comment
tr8er Posted February 17, 2016 Report Share Posted February 17, 2016 Just clamp a piece of 3/4" ply to the aluminum. Drill through the plywood with the aluminum behind it. The plywood will guide the hole saw straight without chance of straying. Better than water or oil. A punch set beats all of this though. Hole saws are like butter knives for suicide. Quote Link to comment
B210GX Posted February 23, 2016 Report Share Posted February 23, 2016 Depending on your hole size and or shape...I use a flush trim router on an MDF template with a wax like lubricant(cant remember the name) edit : found it I have cut thousands of feet of holes in aluminum. I used to make Jeep diamond plate parts and half doors and sell on fleebay. 2 Quote Link to comment
jesusno2 Posted February 23, 2016 Report Share Posted February 23, 2016 Annual cutters work great for sheet metal but they are expensive far superior to a hole saw 1 Quote Link to comment
Mattndew76 Posted February 23, 2016 Report Share Posted February 23, 2016 If I could afford it. this is what I would use all the time. 1 Quote Link to comment
jesusno2 Posted February 25, 2016 Report Share Posted February 25, 2016 Thats cool!^^^^ Quote Link to comment
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