Hole Cutting in Sheet Metal

[inchpincher]

What's a good way to cut large round holes in sheet metal? I found this tool in the US but can't find an equivilent in the UK...
Only seems to cut a max of 1mm gauge too
Malco Hole Cutter

Thanks,
Ben

 

[MrFluffy]

Theres lots, depending on how big a hole you want to cut. The keyword in the uk is "tank cutter" as they were originally made to cut holes in tanks to attach flanges.
eg :-
http://www.tool-up.co.uk/shop/diy/MON79.html?id=DPN9PZLE

 

[peterd51]

Hi,

that looks an interesting bit of kit...

I must find something that needs a hole!

Regards
Peter

 

[inchpincher]

Thank you. Never thought of 'tank cutter' which is ironic because I need to cut a hole in a fuel tank.
So thats the hole sorted, but I also wanted to weld on a 'collar', basically a thick plate washer that I could weld to the tank hole and tap threads in to attach a fuel gauge sender.
My thoughts were if I could find a decent hole cutter I could make the plate washer too ( I think 3mm thick?!?) because I can't find pre-fab ones anywhere!

Ta,

Ben

 

[Hitch]

For what size you probably want, id use a holesaw. I find them much easier to use than tank cutters.
For a fuel tank you only want about 60-70mm?

And the outside 'collar' just cut to a rough shape with a cutting disc then a flap disc to final shape.

 

[premmington]

I use hole saws, sourced from screwfix, you can buy them singularly in most common sizes. Have found screwfix own make holesaws ok & allot cheaper than Bosch range they sell.

Trick is to cut trial hole in a piece of scrap, as holes produced tend to be slightly larger than size on cutter.

Have cut 60mm hole in 6mm plate with one, very slowly using cutting oil. Using slow half inch air drill. Its was slower but neater than me using a torch.

http://www.remmington.plus.com

 

[Hitch]

I can vote for the screwfix own brand holesaws. Excellent quality and price.
I tried the bosch ones, with the quick release arbor a while ago. I wasnt at all impressed, there far to much wobble in them to be of use.

 

[inchpincher]

Thank you gents, down to screwfix it is.

ben

 

[rusty69bus]

another one, 173mmm hole i need to repair a headlight mount?

 

[Paul.]

At that size you should be able to jigsaw it,

 

[shenion]

Here's a tip on the hole saws. I find they chatter and end up widening the pilot hole and the result is usually a ragged hole.

Replace the drill bit with a piece of round bar or install the drill in backwards. That way it won't "mill" its way around. Then drill the pilot hole with a regular drill.

 

[Hitch]

Yep, id go for a jigsaw aswell.

 

[Welderpaul]

Here's a tip on the hole saws. I find they chatter and end up widening the pilot hole and the result is usually a ragged hole.

Replace the drill bit with a piece of round bar or install the drill in backwards. That way it won't "mill" its way around. Then drill the pilot hole with a regular drill.

Good thinking. Might try that.

 

[rusty69bus]

trouble is i need to make about quite a lot, maybe i should look at getting someone to plamsa/laser or waterjet cut them steel needs tobe 1.2mm

 

[Hitch]

Laser if its worth the premium...

How many do you need then?

 

[rusty69bus]

40 to make 10 light surrounds

 

[Hitch]

That is a fair bit of jigsawing

 

[rusty69bus]

yep, iwas hoping to go the hole saw root as i could use the cut out hole and the sheet itself but the biggest seems 150 ish

 

[Hitch]

I think i hvae only seen upto 152mm, they take some turning!

How about a trepanner if you want to keep both bits...?

 

[rusty69bus]

good idea but any idea where i could get a semi decent one from, i was thinking an edwards circle cutter