What have others found to be the best way to cut/drill aluminum dash panels to add gauges?

Are you going to do it with the dash still in the boat?... Or remove the gauges and dash?....

It's a side dash panel that I would rather leave in the boat. There is access below.

You are going to have to use a hole saw with a pilot drill bit. This is the same kind used for wood.It will work on the aluminum without any problem. Milwaukee makes them. So do several others. You will need a very slow moving drill, preferably a small drill... Don't get one of those huge drills with a gear reduction to slow the bit. If the saw grabs in the aluminum the drill will break your arms. NO KIDDING.. Drill the pilot where you want the hole and then attack it with the hole saw. Use plenty of WD 40 to keep it cool and take your time. When the saw begins to go through be careful that it doesn't grab. Good luck. Keep in mind that the hole saw makes a hole slightly bigger than it says. So.. if you use a 1.5 hole saw... you are going to get a hole about 1/8th of an inch bigger. So practice on a scrap piece to make sure the bezel covers your work.

Sounds like a cordless drill just might be the ticket.... the hole size for standard gauges is 2 1/16" so a 2" hole saw should be the one..... and I even have one of those. Many thanks.

Might find a scrap peice of alum to test the actual hole size first. If it drills right to size, then you will have to use a file to open it up. Or you can always bend the pilot drill a hair to make it drill over size.

if the dash is painted drill from the top down put masking tape over the painted area where the gauge will go. drill your hole then peel the tape from edges towards the center of the hole. this will prevent the paint from chipping around the perimeter of the hole. ratman

If you dont feel comfortable drilling with the saw there is a special tool made for aircraft gauges. It pops a hole in aluminum dashes. I just cant remember were they are sold.

A cordless drill with a clutch would be nice. The hole WILL be bigger when drilling in metal.

I think Harbor freight sells them, they are tits, drill a hole and thrad it and it punches the hole out when you tighten it down. If you opt for the hole saw, make sure its one that has the chuck that is D shaped, so the hole saw wont wobble as its going in, the D shape centers it to run in a true circle. Use Tape and then tape over top of the tape. did I mention tape?