Make A Bushing That Pilots Off Of The 1/4" Bit On You Hole Saw That Has A O.d. Slightly Smaller Than The Current Hole. Sometimes You Can Place A Smaller Hole Saw Inside Of The Larger One And Use This As Your Pilot. Good Luck.

I cobbled this up when I needed to make exhuast holes 4 1/2" from 4" Did not want the hole off center so the big piece is 4" exactly with the pilot hole in the center. Then use a 4 1/2" hole saw. Attach to back side of transom. Something like this should work for ya....only smaller

Dan

You need to upgrade hole saws. Some of them use a separate bit that is tightened down with an allen screw. If you have that type, you can either move the bit or replace it with a longer one.

Or, you could always mount the piece of plywood you are using as a guide to the front of the dash instead of the back. Just a thought. It worked for me a few years back when I replaced my steering and didn't have any clear access to the back of the dash.

They also make a special bit that allows you to mount two saws. The smaller one locates the hole.

Duck Tape the backside, then make a plywood plug and insert it with
bondo or epoxy. Let it cure for a half hour, and drill your new hole.


Duck Tape will keep your plywood plug from falling through.
And your bondo or epoxy from running all over.

You can also run a few rows of masking tape on the topside.
Trim the hole with a razor, stuff your Plywood Plug and bonding
agent up against your Duck Tape.

Then if you make a mess it won't be bonded to your good surface.
Just peel your tape on both sides when done, she'll look new.



Cougarman

Take a hole saw the size of the old hole and then the hole saw the size of the new one. Put the new hole on first, then put the hole saw that is the size of that hole in the picture on next. The smaller one will stick down a bit more and guide ya in there.

Jon

Oh and if your hole is not going to be that much larger then you can on most hole saw guides extend the depth that the centering drill will drop. There is ussually a set screw in the chuck to allow you to drop the bit quite a bit.

Jon

Audiofn is exactly right. I've done it many times. If your hole saw mandrel doesn't allow you to stack then go buy a better mandrel.

One hole . a gazillion ways .....

Call these guys... Your Hole is their goal!