[MikeyRide]

I fitted my power brake booster last night so I had to enlarge the hole in the mount. I used a combination of a sawzall, drill, 3" air cutter, and a file to clean up the mess. I'm sure there's a "right" way to do this. So, what tool am I missing?

Similarly, what's a good tool for making cuts (particularly inside ones like for a heater) in the aluminum panels? Nibbler? Rotary cutter?

Thanks.

 

[KobraKurt]

2 1/4" or 2 1/2" hole saw and a little bit of light oil. Much neater and cleaner

 

[KobraKurt]

I used a rotary cutting wheel and my compressor last night to cut the hole for my heater. Took a while (I think I need the BIG compressor) and a nibbler would probably be better, but my lines were straight and it didn't scuff up the firewall.

 

[Jeff Hamilton]

I use a holesaw. C-clamp a 2x4 across the hole and redrill it.
Jeff Hamilton

 

[forrest1]

A plasma cutter makes quick work of it.

Forrest

 

[swydra]

I just used a 2X4 with a piece of metal with a 1/4" hole to hold the center and held it to the back side with drywall screws. Use lots of oil or you will no longer own a sharp hole saw.

 

[rhygin]

Hole saws are THE "I dont have a lot of tools, i.e. drill press" tool for this stuff

 

[Wade Chamberlain]

I clamped a piece of 1/4" steel across the back side and used a hole saw like everybody else. However, in hindsight, I should have used this as an opportunity to convince Beth that I NEED a plasma cutter.

 

[Jeff Hamilton]

Drill press????? I used a electric hand drill. I'll bet you it would be hard to use a drill press.
Jeff Hamilton

 

[MikeyRide]

Originally posted by Jeff Hamilton:
I use a holesaw. C-clamp a 2x4 across the hole and redrill it.

Nice. Much better way to do it.