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Old 11-11-2012, 07:04 AM   #16
Al Tuna
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I click on a thread... and common sense has me beat every time.
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Old 11-11-2012, 07:20 AM   #17
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I click on a thread... and common sense has me beat every time.
The title did not say need A-hole.


Hiya Tuna.....


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Old 11-11-2012, 07:24 AM   #18
Al Tuna
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The title did not say need A-hole.


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Old 11-11-2012, 09:16 AM   #19
JStory
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How exact do your holes have to be? An electrical knockout cutter can cut
your round hole in seconds. A 3" conduit knockout is about 3.5".
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Old 11-11-2012, 01:13 PM   #20
Bloodweiser OP
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have some wiggle room. It's a cutout for a tach.
Tach body = 3 3/8"
Bezel is ~1/4"

I'd like it to be as snug as possible,
guess I could pad it out with some rubber or electrical tape.
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Old 11-11-2012, 01:44 PM   #21
MotorradMike
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Is there a reason you can't use aluminum?
Things get easier.
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Old 11-11-2012, 04:20 PM   #22
speedracertdi
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Jigsaw, fine tooth blade, and a little WD-40. You'd be there all week with a Dremel.
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Old 11-12-2012, 03:54 AM   #23
josjor
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With the tools you have I would just chain drill it.

1. Mark your 3 3/8 circle.
2. Use an 1/8" bit to drill a series of holes that touch/almost touch around the INSIDE perimeter of your mark.
3. Once you're all around the circle, you can knock out or wiggle the piece to remove the center.
4. Smooth and fit the final hole with a half-round file.

Should take you about 15-20 minutes with a good bit. Over the course of four years in the USAF working on bombers and tankers I would be afraid to count the number of holes I've cut this way.
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Old 11-12-2012, 04:54 AM   #24
jules083
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You need one hole right? Ever plan on drilling a hole that size again?

Go to a machine shop. By the time you mess around with getting it 'close' you should be able to get it done for a few dollars.

Otherwise I'd probably chain drill it or use a jigsaw. I'd probably make a practice cut inside the hole with a jigsaw to see how it looks then go from there.
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Old 11-12-2012, 05:28 AM   #25
LuciferMutt
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For round holes in sheet metal, use a chassis punch of the desired size. See here: http://www.mcmaster.com/#chassis-punches/=k4qaw6
(shipping is fast from this company)

Taking it to a machine shop is very likely to have you end up paying a minimum one hour charge which will be at least $60, unless the shop is small and has nothing else to do or you know somebody who works there. This is especially true if you ask them to do both the hole and the rectangle cutout. A waterjet shop is almost certain to charge you a minimum one hour fee. The abrasives in the water are not cheap and they are generally not reclaimable.
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LuciferMutt screwed with this post 11-12-2012 at 05:34 AM
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Old 11-12-2012, 08:55 AM   #26
bomber60015
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+1 on aluminum -- it works very nicely with woodworking tools (lower the speed), and looks great - - - - I grok using material that's on hna, but there no need to make things tough on yourself . . ..
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Old 11-12-2012, 12:56 PM   #27
H96669
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Go buy one of them diamond coated round hack saw blades.About $5.00 or less. Drill one hole about 1/2", put blade through and install on hack saw. Cope away....!
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Old 11-12-2012, 08:20 PM   #28
anonny
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Scroll saw, jig saw.
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Old 11-13-2012, 02:28 PM   #29
ttpete
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Originally Posted by LuciferMutt View Post
For round holes in sheet metal, use a chassis punch of the desired size. See here: http://www.mcmaster.com/#chassis-punches/=k4qaw6
(shipping is fast from this company)
They want $320 for a 3" Greenlee punch.....

If there's only one hole, I'd buy a Harbor Freight jigsaw and cut it and then have a jigsaw for other projects.
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Old 11-13-2012, 07:50 PM   #30
P B G
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Just buy an appropriate hole saw, Then use it to drill a hole through 1/2" wood (plywood is fine).

Clamp the plywood over where you want your hole, and remove or shorten the central drill so it doesn't protrude too far, you want the hole-saw into the plywood before you start.

Second the handle to keep it from torquing on you, but in addition to the plywood you won't wander off center on the material.
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