Cutting an access hole

[tomn3]

I need to cut an access hole inside my console(190 CC). The deck in there appears to be thin metal, not fiberglass.
This is for access to the fuel pick up and main fuel line.

Is there an easy/safe way to do this? Access it terrible. Do they make a large hole punch for metal that you slowly tighten and it custs through? I've seen smaller ones.
Thanks

 

[TerryMSU]

Re: Cutting an access hole

Yes they do make these sorts of things for cutting holes, but they are not cheap in larger sizes. Greenlee is one manufacturer. You will require a center hole to start the punch in. What about a hole saw? Would that work? Otherwise a nibbling tool could do the job.

TerryMSU

 

[zopperman]

Re: Cutting an access hole

What about a hole saw? TerryMSU

X2 on the hole saw.

 

[tomn3]

Re: Cutting an access hole

Thanks,
The hole saw was a thought. But it's right over the gas tank and it is metal. I can lay some protection in there but I am worried about sparks, etc.
The nibbling tool might be a good idea.

 

[tomn3]

Re: Cutting an access hole

I assume the nibbler still needs a starter hole drilled?

 

[fishrdan]

Re: Cutting an access hole

The metal should be aluminum, so no spark there. I would use a hole saw, start by drilling a 1/4" pilot hole, replace the the hole saw's drill bit with a short 1/4" rod, then slowly cut the hole. The short rod won't punch a hole into your gas tank like a long drill bit would, in case you slip. Finish the access hole off with a deck plate.

 

[zopperman]

Re: Cutting an access hole

I plan on using a hole saw for my deck plate... I was gonna pre drill it, but I guess if you don't have that option, fishrdan's got a great idea for you!

 

[QCBigDog]

Re: Cutting an access hole

I've been in tight spaces and if you go to your local hardware/box store you can find a universal point bit for metal in the electrical tool area or drill bits, next the key is to find one that has a hex shaped drive that can be used in a flexible drive extension for a cordless drill. Most all will have both items- nice thing about this bit is it isn't long so you won't over drill

 

[tomn3]

Re: Cutting an access hole

Well I went out and tried tonight but after removing another access ring it turns out it's fiberglass. About 3/16". So I had the wrong tools. It's a big hole I'm expanding to so I can't use a hole saw. I think a small hand saw.
A drill seemed to do through pretty easily. What do people use to cut fiberglass? 5" circle.

Thanks

 

[NYBo]

Re: Cutting an access hole

This should work.

 

[produceguy]

Re: Cutting an access hole

This should work.

Thats a great deal.

Tomn3, could you cut it out with a jig saw if you don't want to buy the hole saw?

 

[zopperman]

Re: Cutting an access hole

16 bucks!?!?!? I paid 20 for my 3" hole saw alone!

I have to invest in one of those.. I need one tomorrow though! I might be using the scrolling jigsaw myself

 

[soggy_feet]

Re: Cutting an access hole

Yeah, but your 3" is probably one of the solid ones that's good for metal. Those band ones are only good for wood/fiberglass.

I was gonna add, that if you're expanding a hole and need a center for the hole saw, you might try screwing a piece of plywood over the hole to get you started, then drill thru the wood and fiberglass with the hole saw.

 

[tomn3]

Re: Cutting an access hole

That hole saw kit looks great. But I don't want to wait. Someone on another thread mentioned a dremmel attachment.

 

[robert graham]

Re: Cutting an access hole

Harbor Freight carries an el-cheapo hole saw kit for about $5, works great for those every-now-and-then projects, has maybe 8 or 10 different diameter saw blades, but maybe not 5" diameter.

 

[dingbat]

Re: Cutting an access hole

A dremel with a router bit will cut the stuff like butter. Worked great when I cut my dash to flush mount my GPS