Jump to content

How to cut smooth holes in aluminum with a hole saw.


Profile

Recommended Posts

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.

  • Like 3
Link to comment
  • Replies 9
  • Created
  • Last Reply

Top Posters In This Topic

Top Posters In This Topic

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.

Link to comment

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

 

 LPS_Laboratories_43200.jpg

 

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.  

 

FishO8005.jpg

  • Like 2
Link to comment

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

Loading...
×
×
  • Create New...

Important Information

By using this site, you agree to our Terms of Use.