wieland77

iTrader: (1)

I'm doing a new gauge panel, out of aluminum, and cant seem to find a 4 5/8" hole saw to make the cutout for the Speedo & Tach anywhere? 4 1/2 is common but havent tried it because i dont want to mess up my new dash quite yet and Livorsi says its a 4 5/8 cutout. Will a 4.5 work with a little filing? Only making the two holes and if I have to file them out I guess I can, just curious is all. Thanks, MIKE

ICDEDPPL

iTrader: (1)

http://www.pexsupply.com/Lenox-30074...Saw-10298000-p

lowes:
http://www.lowes.com/pd_81544-28303-...ductId=3120989


http://www.fastenal.com/web/products...ex?sku=0223043

etc etc

Cole2534

iTrader: (1)

You doing this on a mill or drill press?

Either way, have that piece locked down tight!

32hustlin

If you can't find what you want in a hole saw, just make a 4 5/8 hole with a router. Attach the base to a piece of wood measure 4 5/8 from the outer edge of the cutter down your piece of wood and drill a small hole then screw the assembly to a piece of plywood through your hole and cut your circle. You then have a jig to follow for your hole. Sounds like a lot of work but it can be done in less time than it takes to go to lowes to look for a holesaw

sbslinde

Worst case, if you bring the dash to me, I can cut the holes for you.

Jeff

wieland77

iTrader: (1)

Ya, already checked Lowes and Home Depot and neither one have that saw. Making a jig for a router sounds like a good idea, might try that. Thanks for the responses guys

OCCJoe

iTrader: (13)

I've drilled more holes in aluminum then you could imagine and one thing I can tell you is that the hole saw is going to wobble . I usually use one size smaller then recommended and file a little after for a nice fit .
You need to find a scrap piece of aluminum and drill a test hole with the 4.5 you have now . You might find that you won't need a bigger one . Test holes in wood or plastic wont work because the bit is going to cut in fast and hold its lines .
Look around , I'm sure one of your friends or neighbors has an aluminum tool box in their trucks you can sneak a test hole in ...

US1 Fountain

iTrader: (1)

If you find the right size saw, do a wood peice 1st. Then clamp that over your panel to keep the saw steady as you go thru the AL. Or use a 4.5 and finish off with a dremel

Ironsales

RotoZip or dremel with a circle attachment and metal cutting bit. You will be able to make a circle from 3/4" to 12". If you need a larger circle you can purchase flat bar stock from Home Depot and extend the center point. Just made one so that I could cut a 20" circle. Bar is long enough to cut probably a 64" diameter circle. As others said make some test cuts on your material to make sure bit will cut right way and size for fit.

wieland77

iTrader: (1)

Thanks for all the advice guys, much appreciated!