Replies

1. 
   renosteinke | Mar 31, 2009 11:47pm | #1

   There are several methods for making those holes. Wereally need the actual thickness of the metal - is it close to 1/8", 1/4", or thicker?  Is the metal steel, hard steel, or stainless?  Etc.

1. 
   DavidxDoud | Apr 01, 2009 12:03am | #6

   mild steel ~.25mm or ~3/32""there's enough for everyone"

1. 
   renosteinke | Apr 01, 2009 12:26am | #11

   Do NOT use anything that resembles a 'normal'drill bit; it will grab, leave a ragged hole, and possibly hurt you and the drill.

   You're pushing the limits of a stepdrill, but that would be my first choice. Wear safety glasses; those things can really throw chips.

   A better choice would be either a Greenlee 'high speed cutter' or Hougen 'rotary broach.' These cutters, which resemble hole saws, work quite well. Keep the rpm's slow, and cutting fluid in the cut. Check electrical suppliers, welding suppliers,and professional tool shops for them.

   A 'knock-out' or 'chassis' punch will do it easily. You need access to the back side of the panel, though. 7/8" is the size usually used to make an opening for 1/2" pipe.

   Finally, hole saws are easily found, but don't work as well as the other methods.

1. 
   DavidxDoud | Apr 01, 2009 12:31am | #12

   thanks - a nice set of greenlee knock-out would look nice in the tool line-up, but the cost/hole is prohibitive, given how seldom they'd be used - thanks all - we'll see what 'True Value' will offer up later tonight - "there's enough for everyone"

1. 
   EricPaulson | Apr 01, 2009 01:23am | #13

   going along with reo..............ask your electrician buddy to lend you a hand in exchange for some peaches.

   I have a set of Rigid hole saw I think I piad 30-40$ for and have use them several times on thinner mild steel. 

2. 
   AitchKay | Apr 01, 2009 03:57am | #17

   Naah, a step drill will do that standin' on its head! I've got one that's gotta be 1 3/8" dia, and it works fine. I like the way they deburr the hole with the next dia. step up -- very clean and smooth.Also, if you want a hole exactly centered, there's nothing better -- start with a 1/8"-starter bit, and switch to one of the larger ones.Some of the larger ones don't even have starter pilots, though -- you have to have at least a 1/2"hole to get the first step in. AitchKay

2. 
   ponytl | Apr 05, 2009 02:17am | #31

   LOL... man when you said thick... i'm think'n 3/4"  maybe 1" or better....

   and yes a regular bimetal hole saw whould cut that hole in less time than it took for you to post the question...

   i built some pivot mounts this morning use'n some 3/4" scrap... for me anything over 1/2" thick and 3" wide  slows me down...  just cause i work with 3/8" stuff all day and am set up to cut/punch and saw it...  1" think and above really slows me down...  thats torch time

   :)P   good luck

2. 
   Sphere | Mar 31, 2009 11:52pm | #2

   Yes they do, but I'd get a Silver and Demming 7/8ths bit. Most hardware stores have em. Maybe 13.00.

   Start with a smaller size and work up...like 1/4 to 1/2 to 7/8.

   Spheramid Enterprises Architectural Woodworks

   Repairs, Remodeling, Restorations

    

   They kill Prophets, for Profits.

    

    

1. 
   DavidxDoud | Apr 01, 2009 12:08am | #7

   a trip to the hardware is on tap a little later today - here's a link to northern tool - http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200307696_200307696they look like 'regular' steel twist drills, I guess? - we'll see what they have - "there's enough for everyone"

1. 
   Sphere | Apr 01, 2009 12:18am | #9

   3/32? Hell, you can do that with a knock out punch set.

   But you ain't got that either I guess.(G)

   Easy witha step bit, even a decent cordless drill can do that.Spheramid Enterprises Architectural Woodworks

   Repairs, Remodeling, Restorations

    

   They kill Prophets, for Profits.

    

    

3. 
   Dam_inspector | Mar 31, 2009 11:59pm | #3

   Get a step bit. Even Lowes has em. They don't grab like a silver and deming does in thin steel.

1. 
   Sphere | Apr 01, 2009 12:01am | #5

   I just checked mine , yer right it goes to 7/8. I have another that goes to 1/2". Didn't cross my mind for thick metal, cuz ofthen you need to come from both sides if it's fatter than 5/16th or yer there all day.Spheramid Enterprises Architectural Woodworks

   Repairs, Remodeling, Restorations

    

   They kill Prophets, for Profits.

    

    

4. 
   Piffin | Mar 31, 2009 11:59pm | #4

   You have a step bit and patience?

    

    

   Welcome to the
   Taunton University of Knowledge FHB Campus at Breaktime.
    where ...
   Excellence is its own reward!

1. 
   DavidxDoud | Apr 01, 2009 12:13am | #8

   I have both, but neither are in good condition - my drill selection is weak too - I've a bosch 1/2" hammer drill that's about ready to give up - I look at those silver and deming bits and my wrists hurt already - I've had a nice milwaukee 1/2 drill in my amazon shopping cart for several months, waiting on some tool money to magically appear - situation normal - "there's enough for everyone"

2. 
   IMERC | Apr 01, 2009 02:49am | #15

   that's what drilled yur sink without the patience... 

   Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->

   WOW!!! What a Ride!

   Forget the primal scream, just ROAR!!!

    

   "Some days it's just not worth chewing through the restraints"

1. 
   Piffin | Apr 01, 2009 05:53pm | #24

   Yeah, I took that lesson and bought a couple in different sizes. I figured he had thicker metal so some patience time was called for - unless it is really soft stuff. 

    

   Welcome to the Taunton University of Knowledge FHB Campus at Breaktime. where ... Excellence is its own reward!

1. 
   IMERC | Apr 01, 2009 06:40pm | #26

   cake and pie for what David has..
   they are so versatile... for what you get for the money, well worth it...so you liked that trick didja... 

   Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->

   WOW!!! What a Ride!

   Forget the primal scream, just ROAR!!!

    

   "Some days it's just not worth chewing through the restraints"

5. 
   cameraman | Apr 01, 2009 12:24am | #10

   How about a 12 gague slug???

6. 
   IMERC | Apr 01, 2009 02:48am | #14

   Lenox hole saw...

   http://www.lenoxtools.com/enUS/Products/HOLE_SAWS.html

   twist bit....

   http://www.heavydutystore.com/silver-deming-drills-c-696.html

   step bit... (rated for thicker metal)

   http://www.irwin.com/irwin/consumer/jhtml/brandProducts.jhtml?brand=Unibit

   10 ga or less use a Greenlee Slug buster...

   http://www.mygreenlee.com/Products/main.shtml?p_search=slug+buster&greenlee_category_id=2&Submit=Find

   Millwaukee steel hole hogs or hole cutters...

   http://www.milwaukeetool.com/webapp/wcs/stores/servlet/category_27_40028_-1_201154_192327

   slow speed and wax for lubricant..
   maintain even pressure while drilling.. don't see saw the pressure or you can kiss the bit adios...

    

   Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming

   WOW!!! What a Ride!

   
   Forget the primal scream, just ROAR!!!

    

   "Some days it's just not worth chewing through the restraints"

1. 
   DavidxDoud | Apr 01, 2009 05:01am | #18

   stopped by the hardware tonight - they had a hook for that Irwin step drill - it was empty, but the price was posted - $50.99I'll be making the holes with the torch before I spring for that one - "there's enough for everyone"

1. 
   IMERC | Apr 01, 2009 05:03am | #19

   http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200307292_200307292one quick look... 21.99$... 

   Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->

   WOW!!! What a Ride!

   Forget the primal scream, just ROAR!!!

    

   "Some days it's just not worth chewing through the restraints"

1. 
   DavidxDoud | Apr 01, 2009 05:07am | #20

   that's the one that goes up to 1/2" - they had that on its hook - don't remember exactly, but under $30"there's enough for everyone"

1. 
   IMERC | Apr 01, 2009 05:13am | #21

   that one goes to 7/8" true...
   or 1/2" electrical fitting....
   go down the page and look at the image and not the specs... 

   Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->

   WOW!!! What a Ride!

   Forget the primal scream, just ROAR!!!

    

   "Some days it's just not worth chewing through the restraints"

2. 
   DavidxDoud | Apr 01, 2009 05:24am | #22

   I have to agree that the image shows clearly 7/8" - which doesn't match the description - anyway, I'm going to try my in stock unit that I inherited from somewhere - it's big enough, but rather stubby - maybe it'll wear its way thru - "there's enough for everyone"

3. 
   danski0224 | Apr 01, 2009 04:16pm | #23

   They probably use the same image for similar tools.

   I would go with the description in this case. The step bit with a 7/8" size is $39.99.

   http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200307296_200307296

   If you want to support China instead of the USA, these are cheaper:

   http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=96275

4. 
   IMERC | Apr 02, 2009 03:06pm | #29

   double checked.. the #4 Unibit does 7/8 holes.. 

   Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->

   WOW!!! What a Ride!

   Forget the primal scream, just ROAR!!!

    

   "Some days it's just not worth chewing through the restraints"

5. 
   Piffin | Apr 05, 2009 12:58am | #30

   http://cgi.ebay.com/TITANIUM-STEP-DRILL-BIT-1-4-TO-1-3-8-CUTTING-TOOL_W0QQitemZ330319116894QQcmdZViewItemQQptZWoodworking?hash=item330319116894&_trksid=p3286.c0.m14&_trkparms=72%3A1205%7C66%3A2%7C65%3A12%7C39%3A1%7C240%3A1318%7C301%3A1%7C293%3A1%7C294%3A50 

    

   Welcome to the Taunton University of Knowledge FHB Campus at Breaktime. where ... Excellence is its own reward!

2. 
   popawheelie | Apr 01, 2009 06:13pm | #25

   They are exspensive. I have one small step bit. I've never sprung for the larger one.

1. 
   DavidxDoud | Apr 01, 2009 06:52pm | #27

   got it done - and after a bit of clean up grinding the holes are just fine - the control cables entered the sprayer at an altitude that put strain on the seals - original equipment f-up, one of the old cables finally seized to where I couldn't get it freed this spring - now I find that the clevis ends on the new control cables are a different thread than the original, so back to the internet and wait a few more days - situation normal - "there's enough for everyone"

7. 
   danski0224 | Apr 01, 2009 02:56am | #16

   Use a step bit, or the brand name Unibit.

   Easiest way to do this.

   You will regret using a regular drill bit.

8. 
   gfretwell | Apr 01, 2009 07:04pm | #28

   A vote for a knock out punch. It makes a nice clean hole and will cost less than a step bit. You will be surprised how handy it is if you do much with 1/2" pipe or anything close to that size.