30mm hole in 35mm thick cast steel - "hand-held" tools only

[Spark plug]

Imagine that bit catching. The drill won't stop that's for sure

Your right it doesn’t stop, the world starts turning. Ask me how I know

 

[skotl]

Wolf drill, 45mm drill for scale

View attachment 299173

Great idea! Henrik probably has too many elbows, anyways

 

[skotl]

Oooft... no wonder the step drill and whatever it was mounted in gave up the ghost! Step drills aren't really intended for cutting material any thicker than each step. To be honest, I'm impressed it got that far before giving up!

 

[Kram]

as above i have done this but drill a couple of through holes in the path of the hole saw for swath to escape

Thanks I will need to try this!

 

[slimjim]

Your right it doesn’t stop, the world starts turning. Ask me how I know

I remember those as an apprentice, you could break your leg if you weren’t careful or quick.

 

[Guzrik]

Strap and clamp a small pressdrill on top of the frame? And then do all of the above with a holesaw.

 

[500e]

There are extra deep hole saws, got a 32 x 180mm 18 tooth.
Neded clearing every 20 seconds or it jamed but I was cutting steel was using flood coolant

 

[Brad93]

If it's cast, it will drill with a hole saw nicely

 

[clift_d]

Front view (excuse the mess, still in the middle of moving into the garage)

View attachment 299171

Yep - a mag-drill is definitely the way to go with that. Just bridge a piece of 10mm plate across the top, clamp/bolt it down good and solid, and then use that as a temporary flat base for the mag-drill to perch over the hole location.

 

[Windy Miller]

Good point

Bromley (London/Kent borders, I guess)

I'm near Rochester so not too far away, and I have a mag drill. If you fancy a trip down this way I'd be happy to oblige.

Not sure if I have a 30mm cutter though but we could always get one...

 

[500e]

Self employment is an option then your the fatcat

 

[Windy Miller]

Self employment is an option then your the fatcat

Wrong thread maybe?

 

[Henrik]

I'm going to attempt it with a hole saw, I think.. if that fails, then I will possibly take you up on your offer @Windy Miller , assuming I can get the base into the boot of the car

 

[gaz1]

if you are drill it with a relief hole first so the offcuts can drop out of the bottom while its being cut

then set your drill up so the hole cutter is at edge of your relief hole as it should keep the hole cleaner for you as you drill it

 

[Henrik]

if you are drill it with a relief hole first so the offcuts can drop out of the bottom while its being cut

then set your drill up so the hole cutter is at edge of your relief hole as it should keep the hole cleaner for you as you drill it

i will try this too

 

[gaz1]

 

[Ton-up]

I can make a 30 mm hole and post it to you if that's any good..........

 

[James1979]

I can make a 30 mm hole and post it to you if that's any good..........

Do you work for polo? Hope you didn’t nick it from work….

 

[Henrik]

So, this is done

I ended up using a 2" holesaw instead, as I had one lying about.

The handheld drill actually worked better than I thought it would. One hole drilled for chip evacuation. My saw cut better with some wd40, but that might be because it didn't have enough power to not bind otherwise, so the friction reduction helped (although it also meant i had to clear the chips a lot of times).

Overall, I had to give the drill a rest many many times as it became so hot it smoked (The makita drill, not the actual bit).


The depth was less than I thought originally - only 28mm deep in the end.

I 3d printed the orange bit to hold the guide drill steady, which surprisingly worked really well.

 

[Munkul]

Good going!