What's the best way to get some nice 22mm holes in 0.7mm ali at regular spacing for my savage switches?

Thanks,

Pat...

hole saw

Hi how about using a chassis punch you can get them in differant sizes
Graham

i cut out a template in card, then with a maker pen i coloured in the area i needed to remove, dilled the hole as big as i could them demeled it

CAD up the area available for the switches, space them evenly using CAD then print it onto A4 masking tape it to the dash and drill

Voila

of course if you cant CAD this aint an option

You might be able to space them in word using the rulers in that

hole saw ... hmmm, my experience is they tend to wander a bit but since the edges of the hole are covered by the switch you should be ok.

My way would be to use a stepped drill, since I have one (don;t by the one freom screfix - it is sh*te)

Forgot about that, a quality hole saw wont wander though but a Xmas tree drill is the way too go.

Yep, this is the way to go...http://www.houseoftools.com/product.htm?pid=16786
I use them, and they work like a charm!!!

My experience with ali:

1: hole punch
2: tapered drill
3: hole saw (but use lots of cutting fluid)

When I use a hole saw with thin alu I always fix the alu on top of some expendable plywood. Reduces the wandering and make the after work much easier.

I haven't tried the dremel way. Should be good but I haven't got the patience...

I'll seconds Zetec7's suggestion, got one from aldi a while back, very good indeed.

R

Stepped drill does it in a few seconds with reasonable accuracy. A cone drill can also be used but is a bit more slap dash

Pat,

i;ve got a 22.5mm punch if you want to borrow it,

just drill an 8mm pilot hole, and wind the bolt in.

gives a nice neat hole

Ray

Pat

Chassis punch would be my choice - like here

Regards

Wyn

I bought a load of different sizes of these

[Edited on 21/2/07 by Mad Dave]

quote:

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Originally posted by jos
CAD up the area available for the switches, space them evenly using CAD then print it onto A4 masking tape it to the dash and drill

Voila

of course if you cant CAD this aint an option

You might be able to space them in word using the rulers in that

---

Cheers.

Think I'll get myself a stepped bit - will come in handy for other holes as well.

Pat...

these

are the dogs bollocks...
Used them to cut out the holes for the exhausts in my ali side panels...
Seriously nice...
....though for a cut-out for switches I'd stitch drill with a small-ish drill. If the ali gets bent at all with the drilling (and hacking that is usually required afterwards), use two repair washers and a bolt to squish the ali flat again....
Quick and easy (and cheap).....

but for a proper job use the bolt-up punches....

so what is wrong with a hole saw and measuring the distances??

I have cut many holes without probs this way.

Problem is i can see that so many of us resort to 'modern' technology. Measure it; Measure it again; mark it and bloody cut it!



J

Stepped drill, nice neat rag-free holes.

Another vote for a stepped drill. Put mine into carbon dash but it worked very well indeed (just dont push on too hard when you are close to final size!)

Did all my dash with a 2mm drill bit and chain drilling.

Then a good half-round file smothed the edges nicely.

Cheers,
James

stepped drill!

i used a hole saw with the ally clamped to some ply.

Stepped drill bit...

Hmmmmm...

Mastered it on my third attempt.

They do tend to wander if you try and use the full length in one go.

Started off with drill bits up to 12mm and then the stepped bit.

Perfect...

Panel ready to be riveted on.

Cheers everyone,

Pat...