Best practic for cutting hole in aluminum dash for new gauges
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Best practic for cutting hole in aluminum dash for new gauges
What have others found to be the best way to cut/drill aluminum dash panels to add gauges?
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Re: Best practic for cutting hole in aluminum dash for new gauges
It's a side dash panel that I would rather leave in the boat. There is access below.
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Re: Best practic for cutting hole in aluminum dash for new gauges
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.
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Re: Best practic for cutting hole in aluminum dash for new gauges
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.
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Re: Best practic for cutting hole in aluminum dash for new gauges
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.
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Re: Best practic for cutting hole in aluminum dash for new gauges
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
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Re: Best practic for cutting hole in aluminum dash for new gauges
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.
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Re: Best practic for cutting hole in aluminum dash for new gauges
Originally Posted by Prater
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.