Drilling gauge holes in new dash

[Banjer Picker]

What is everyones recommendation on the best tool for cutting the circular holes in a new dash for the key hole and other gauges?

In the past when I have used a hole saw on dashes it seems to really do some ripping. Not much finesse to them.

Also, the factory dash had a concave surface for the key hole. How do you recreate that on a new dash?

Thanks!

 

[Broncobowsher]

For the specality holes (like ignition) I cut the hole out of the old dash and welded into the blank.

 

[AZ73]

I drilled a bunch with hole saws that has centering drills, clamped down on a piece of wood, using a drill press.

https://classicbroncos.com/forums/showpost.php?p=2728528&postcount=141

 

[sykanr0ng]

A few things for I have seen mentioned for that are Greenlee hole punches electricians use and water jet cutting.

Greenlee punches are not the size they are labeled, just like a lumber 2x4 is not 2 inches by 4 inches.

 

[bronkenn]

I use the rotobroach cutters. There are a few different names for them. They require a 1/8th inch pilot hole and do a really nice job, just go easy. They have standard size increments and only go to up around 1 inch, maybe a little larger. I believe the larger ones use a 1/4 inch pilot. Ken

 

[Jason72Bronco]

I really like step drill bits for drilling holes in metal. Take your time, and you get perfect holes in the perfect spot. I'm not sure they make them large enough for a gauge opening, but certainly do for a key or switch opening.

https://www.amazon.com/gp/product/B07GL5H8NP/ref=oh_aui_search_asin_title?ie=UTF8&psc=1

 

[Crawdad]

Sandwich the dash in between two pieces or wood or thin metal (like aluminum). Use some clamps near your cutting area and press all together. Line up all your pilot holes and drill away. I’d recommend using brand new metal cutting hole saws from Lowe’s or HD. A drill press is a big help as well.

 

[Broncomt]

Go shopping for high end hole saws, might be HF type. Cost more but a much much better hole in the dash.

 

[LSUpete]

I drilled a bunch with hole saws that has centering drills, clamped down on a piece of wood, using a drill press.

https://classicbroncos.com/forums/showpost.php?p=2728528&postcount=141

Hey,

Do you have any photos of the finished product? I would especially like to see the "push button" ignition start. Actually, I would like to hear how that modification can be done.....cause I might like to add that to a new dash I'm planning.

 

[73azbronco]

DO NOT use the harbor freight hole punch. Cant punch through metal half as thick as the dash.

 

[AZ73]

Hey,

Do you have any photos of the finished product? I would especially like to see the "push button" ignition start. Actually, I would like to hear how that modification can be done.....cause I might like to add that to a new dash I'm planning.

I have a bad picture from my phone and I don't think the Push button was fully installed as it's centered now that it's finished. I'll take a better picture when I get home. I investigated several companies and narrowed it down to Advanced Keys, DigitalGuardDawg and Gallotech. After speaking with them all I liked the Gallotech system and went with them. They were very familiar with Broncos and sold lots to other owners, and I found their customer service to be great. The button sticks to the dash and a wire comes through a small 1/2" hole and runs to a box that controls everything about the size of maybe 2 packs of cigarettes. To get the door lock/window you have to buy the kit that does trunk and some other things, but I just tied those wires off.

I used a step drill bit to do the turn signal lights, bright light indicator, brake warning, and push button key.


https://www.gallotech.com/Keyless-Push-Button-Start-Security-Systems/GTStarter3.php

 

[LSUpete]

I have a bad picture from my phone and I don't think the Push button was fully installed as it's centered now that it's finished. I'll take a better picture when I get home. I investigated several companies and narrowed it down to Advanced Keys, DigitalGuardDawg and Gallotech. After speaking with them all I liked the Gallotech system and went with them. They were very familiar with Broncos and sold lots to other owners, and I found their customer service to be great. The button sticks to the dash and a wire comes through a small 1/2" hole and runs to a box that controls everything about the size of maybe 2 packs of cigarettes. To get the door lock/window you have to buy the kit that does trunk and some other things, but I just tied those wires off.


https://www.gallotech.com/Keyless-Push-Button-Start-Security-Systems/GTStarter3.php

I can see why. That Gallotech system is $250 cheaper than the DigitalGuardDawg.

 

[sanndmann3]

I used an adjustable hole saw similar to this:
https://www.ebay.com/itm/Adjustable...904943&hash=item4d745d79ad:g:XKYAAOSw4RZbCNgH

went slow and easy and lots of cutting oil. It was pretty much shot after 6 holes but got it done.

AZ73, looks like great minds think alike!

 

[74 Bronco Billy]

I used an adjustable hole saw similar to this:

https://www.ebay.com/itm/Adjustable...904943&hash=item4d745d79ad:g:XKYAAOSw4RZbCNgH



went slow and easy and lots of cutting oil. It was pretty much shot after 6 holes but got it done.



AZ73, looks like great minds think alike!

You can resharpen the cutter in that bit many times. Use a diamond stone. Slow with lots of cutting oil, drill press and patience.
For Smaller holes the Blair rotabroaches work really well, Amazon has 2-3 sets, one with larger holes. Great for heater hose, AC and electrical wiring holes. They hold onto their sharpness a long long time.

Sent from my SAMSUNG-SM-G930A using Tapatalk

 

[SteveL]

Find somebody with a greenlee ko set. As long as the dies are good it's a perfect clean hole. You can buy a manual one that works like a ps pulley tool with a bolt bearing and a die. The manual ones come up to 2".

 

[KBUCK1]

Step bits for the smaller holes

 

[AZ73]

I used an adjustable hole saw similar to this:
https://www.ebay.com/itm/Adjustable...904943&hash=item4d745d79ad:g:XKYAAOSw4RZbCNgH

went slow and easy and lots of cutting oil. It was pretty much shot after 6 holes but got it done.

AZ73, looks like great minds think alike!

I like it! I went with red lights. As a pilot, that's what we use at night.

Here's slightly better pictures.

 

[Howard2x4x4]

See post 56. I'm pretty sure I used a saber saw with fine metal blade for the speedo and tach holes and for the control holes and I used a hole saw with wood blocking and a drill press for the gauge holes.

https://classicbroncos.com/forums/showthread.php?t=286019&page=4