How to bore/drill/cut holes in aluminum hubcaps to fit front wheel lockouts?

[snick]

I picked up a set of the dog dish aluminum hubcaps. What is the best way to drill out the fronts so the wheel lockouts fit through them. I’m doing this on a budget so I’d appreciate suggestions for the most reasonable but still professional (centered hole, round hole, clean edges, etc) way to have this done? I live in Santa Barbara, CA where there aren’t many options for this type of thing but I don’t mind traveling to Oxnard/Ventura if someone knows of a good shop/person. Also, for those who have done this, what diameter hole did you go with?

 

[phred]

Hole saw is the cheapest way. They make carbide hole saws just for sheet metal. They’re pricey but leave a very clean hole. I would cover the face of the cap with several layers of masking tape. Place the cap face done on a block of wood. Mark the center and drill slowly. A second pair of hands to hold the cap will be helpful

 

[bax]

Hole saw for the win. You dont need the carbide ones. Just a bi-metal standard hole saw will work just fine. Drill the center hole then fun the hole saw in reverse. It will cut without grabbing the metal. Cut it from the backside. I suggest the hole saw center drill be in a piece of wood to help hold it from walking. An extra set of hands is best.

 

[snick]

Really appreciate the hole saw recommendations. Should I use the hole saw on a drill press or with a hand drill? Those are my only 2 options...well I guess a third would be to use a BFH to beat it through but don’t think that would yield the results I’m after.

 

[markyyg]

I think a drill press might give best results, little bit more control and maybe a might safer.

 

[fordguy]

I bought some from SteveW that he had cut maybe you can ask him.

 

[Rustytruck]

If it was my project I would snap them on a spare rim then go through the back using the rim as a guide for the hole saw.

 

[bax]

I like the drill press idea. Still a 2 person job and I would still use a block of wood clamped to the bed of the drill press to help center and keep the hole saw stabile. In my mind the hubcap is upside down on the drill press but if you could find something that was the same shape as the hubcap and clamp that to the table of the drill press face side up. then that could work well too. just throwing out ideas.

 

[Madgyver]

It wasn't me but someone did a great job on these caps. There is a lip folded in.

 

[Yeller]

I chucked mine up in a lathe and cut with a hole saw. Slow and easy wins the game.

 

[GreMac]

I just did this on a set of caps. Stuck them on a loose wheel/tire, found center, predrilled and slowly cut away with a bi-metal hole saw. As expected it'll get pretty grabby as it starts to break through so just take it slow. Then just used a half round file to smooth out the hole and deburr the edges.

 

[snick]

Great info, thanks everyone. Does anyone remember the diameter size they drilled? Going to buy a large hole saw on my way home from work today. Or can anyone measure the largest outside diameter of their front hub/lockout? Thank you!

 

[Rustytruck]

everything I read on the subject was 3-1/2 inches but you better verify before jumping forward.

 

[Yeller]

Mine was 3-1/2