What do you guys cut the exhaust holes with? Trying to use a hole saw but what a PITA.

Will try a carbon tip one Saturday but was wondering if anyone has any tips.

I've used a hole saw in a battery drill with a clutch. take it easy and don't push too hard. Let the saw do the work as opposed to trying to push it aggressively.

What is hanging you up with a hole saw?

Buy a new hole saw and let eat. DON'T push it. Two 5 inch holes in mine.

Vintage,
Just when it catches and try's to break my wrist. Have a new one for this Saturday.

Thanks guys.

That why the clutch drill is critical wildman. I've broken 4 bones in my right hand with a 4.5" hole saw when I was an apprentice by using a regular pistol drill.

I also like to pull back on the saw every 15 seconds or so and clear the teeth of the sawdust. It tends to build up and clog the teeth.

Take your time and it will be an easy and clean cut.

I used a new hole saw to do mine. Did four holes and after that it was junk.

Also be very careful when the drill starts to cut through. If you push it too fast it will tear the fiberglass strings on the inside. If you burn the bit it is done.

What kind of clutch drill you using Vintage?

Tinkerer,

Can't say that to many times,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, I have a brand new hole saw so hope it goes better this weekend. If I get back home.

When the pilot drill breaks thru the opposite side stop drilling and the finish the hole from the other side. This will prevent the shredding of the fiberglass when the hole saw finishes. Be careful to make sure you are very close to the same angle as when you started or you will have created a small ridge inside the hole. And be sure to seal up the hole to prevent moisture from creeping into the wood core.

(just to make sure it makes it thru our typical "I know what Im doing, it cant happen to me" mindset" as has been said watch you azz!!!! I weigh 180, when using a hole saw to ,make the holes in the dash for my tach. the drill caught and lifted me completely off my feet. I have a friend missing a couple fingers when a buffer caught, spun free from his hand and the cord grabbed his fingers and took them off like nothing.