Drilling larger holes

[alldodge]

Have always used hole saws to drill holes above 3/4 inch. Still want to redesign my helm gauges but currently installing another gauge (2 1/8). For temporary purposes this season, I'm removing the speed-o (4.5 in) and installing a plate and new gauge in it.

Cutting thru aluminum so are there better options?

 

[GA_Boater]

Possibly a circle cutter, AD. A quick Google picked up this one at Harbor Freight with dual cutting blades. Many have a single cutter. https://www.harborfreight.com/carbide-tip-adjustable-circle-cutter-68117.html

 

[Harritwo]

We use this type of tool on elec boxes. Depending on the thickness of the plate, this might work better.

https://www.grainger.com/product/GREENLEE-Hole-Punch-Set-4A742

 

[alldodge]

We use this type of tool on elec boxes. Depending on the thickness of the plate, this might work better.

https://www.grainger.com/product/GREENLEE-Hole-Punch-Set-4A742

Yes I have some of those also from Dad's stuff, he was an electrician. Just not one that large.

Annular cutters are said to cut nice holes

 

[MTboatguy]

Unfortunately that Harbor Freight circle cutter is not very good, I have one and it is hard to keep tightened down and gets wobbly. I have a large selection of Milwaukee hole saws, but for the size you need, I would use my Rotozip with the circle attachment. If you have a rental company around they may have something you could rent to do the job.

 

[alldodge]

I have a rotozip and have not tried to do round holes yet

 

[harringtondav]

I have a circle cutter like GA mentioned. It works well with a little practice. Another poster was wondering about cutting a large hole in his fuel tank. I suggested this as an alternative. HVAC guys use these to cut holes in duct work for star collars.

 

[blamtro]

I did this a few years ago and bought hole saws of various sizes up to 6” but if i remember correctly the most common size was 3-4”? Holesaws made it easy once I had the right size.