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

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

You doing this on a mill or drill press?

Either way, have that piece locked down tight!

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

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

Jeff

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

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 ...

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

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.

Thanks for all the advice guys, much appreciated!