Cutting smallish holes

[thepurpleblob]

Probably a silly question - I want to cut neat small holes out of an inner wing panel and let in new metal. Some plastic studs have rusted out and I need to patch the area they live in before drilling a hole for new ones. I would imaging a hole about an inch square will clear the rust. The panel shape is too complicated to take a big chunk out if I can avoid it.

Any tips appreciated.

 

[shenion]

Drill hole then use a nibbler. I have a hand nibbler that i use.

 

[langy]

I would use a holesaw or Q-Max cutter for that and you can also make the new piece with it too.

 

[thepurpleblob]

Thanks! There already is a rusty hole - so no drilling needed. Water must have go to the plastic insert (holds the wheel arch protectors) and rusted around them.

 

[ajlelectronics]

Also known as a tank cutter or chassis punch. Used for valve bases or connectors etc in electronics.

 

[DrNik]

plasma cutter all the way

 

[thepurpleblob]

The punch sounds like a good idea but I don't think I have the space. It's close to a bend so the nibbler sounds like a better idea on this occasion. Sorry - should have got a photo!

EDIT... my wife will kill me stone dead if I say I need a plasma cutter

 

[DrNik]

tell your partner it cant be done without a plasma, normally works with my Mrs, lol its still in the box, never been out yet

 

[thepurpleblob]

She's already wise to the "but you get a lifetime guarantee with SnapOn tools!!"

 

[500e]

But only on the tools

 

[Wallace]

tell your partner it cant be done without a plasma, normally works with my Mrs, lol its still in the box, never been out yet

I'm sure there must be some law against keeping your Mrs in a box. As for the rusty hole, tack a larger plate in and use a holesaw or Q-Max cutter through both as Langy suggested then remove the tacked in plate and fill with new material.

 

[Exuptoy]

I'd invest in either a Dremmel or a cut off tool and hobby compressor. 3 inch air cut off tool and compressor in aldi recently £8 & £100 respectively.

 

[pedrobedro]

Another vote for a hole saw if you can get in with one. A round hole will weld just as or easier than square one with no corners to burn off (Sharp corners always melt quicker)

 

[thepurpleblob]

Compressed air I have... all of the gear and none of the skill.

 

[Wallace]

I'd invest in either a Dremmel or a cut off tool and hobby compressor. 3 inch air cut off tool and compressor in aldi recently £8 & £100 respectively.

Those little air cut off tools guzzle air, my 14cfm compressor struggles to keep up with mine. The Dr Emel cutting discs are good but expensive, another alternative is a plain old set of hand files.

 

[thepurpleblob]

Here we go... the idea is to make the large rusty hole into the slightly less rusty square hole. Thes are replacement bits cut out of a 'doner' car. You should see the panels on my car - well you can't. They're not there any more. It's right between two folded edges.

 

[Robotstar5]

What process are you going to use to weld the coin in the hole?

 

[Sean]

2p are better they are copper flashed steel

 

[thepurpleblob]

Sigh