How to cut 2 5/8 inch Guage Holes

[ripcityracing]

I am about to install some 2 5/8 inch guages in my dash and was looking for some hints. I have hole saws but not 2 5/8ths yet.... I have a plasma cutter, sawzall and a jigsaw.

What's the technique to getting these perfect?

 

[70_Steve]

Try a 2 1/2" hole saw. Usually there's enough wobble that the hole will wind up at 2 5/8". Try it out on a scrap piece first.

 

[grant_71]

IF you have GOOD hole saws, and a good drill and way to hold the work piece, i have surprised myself as to how good of a hole i can cut.

 

[moe d]

dont use anything but a hole saw.. a jig saw or sawzall CAN make it look like crap..

 

[Dusty]

dont use anything but a hole saw.. a jig saw or sawzall WILL make it look like crap..

Fixed it ;D

Dusty

 

[cs_88]

Be careful not to bend your pilot bit.

 

[ripcityracing]

thank you all, hole saw it is. I currently only have 1 3/4 and 2 inch saws that I use in my tubing notcher but I am off to buy a good 2 1/2 inch saw and I will start hacking away this evening....

Thanks again

 

[Dusty]

Couple tips...you MUST use a drill press rather than a hand-held drill motor. Clamp the workpiece very firmly, then throw a couple more clamps on it. Use cutting fluid and go slow. If you have a piece of aluminum plate to use as a backer, that will work better than wood as it won't give as much.

Now that we're on the subject, as anyone ever used a Greenlee punch for this purpose? Do they even make the dies in that big of sizes? Those would make a nice cut but would probably deform the metal a bit.

Dusty

 

[Fishbone]

Now that we're on the subject, as anyone ever used a Greenlee punch for this purpose? Do they even make the dies in that big of sizes? Those would make a nice cut but would probably deform the metal a bit.

Dusty

They are always my first choice for a clean (almost perfect) hole, but off the top of my head... I'm not sure if there's one close enough to 2 5/8".

 

[Pa PITT]

I BELIEVE IF IT CALLS FOR A 2 5/8 THAT'S WHAT i'D BUY I have had to use a file and it's not easy to remove that much.

 

[Apogee]

I've used a GreenLee hydraulic punch for up to 16 ga stainless...didn't like that much, but mild steel is like butter by comparison. Any decent electrical shop, especially one that does industrial controls wiring, should have all of the necessary tools for popping holes in electrical enclosures.

The only issue I've had with the punches is that they tend to deform the surrounding material somewhat if they're dull...probably from some guy trying to cut 16 guage stainless with a set of punch dies not meant for it...

 

[Dusty]

Now THAT is a badass cup holder! Nice job.

Dusty

 

[u10072]

Dude go and buy a 2 5/8" holesaw-- get it from Home Depot and when it burns up they will replace it for free! Trust me its the best $11 you can buy if your building a dash-- that is unless you have a punch of course!

 

[Fishbone]

Now THAT is a badass cup holder! Nice job.

Dusty

Thanks Dusty

 

[deltarat]

I used a 2 1/16 hole saw and the drill press to cut the hole for my tack. It worked great.