What size hole saw for creating front hub caps

[thegreatjustino]

I came across a set of old school Ford two wheel drive hub caps in decent shape at the junk yard today. I'll need to cut holes in two of them to get them on the front.

Anyone know what size hole saw I'll need off the top of their head?

 

[rguest3]

Diameter of Front Hub + some is a good start.

108mm comes to mind, but confirm this.

 

[EricLar80]

Wheels typically have an inner diameter of 4.25" to fit over the hub, so I assume the hub itself is about 4" or a little smaller. I would probably shoot for 4" if I could, but measure to make sure it would work.

Eric

 

[markw]

Hi Justin, I just did this. Use a 3.5 in hole saw. I filled the inside of the hubcap with plaster and a chunk of closet pole to support the metal. Use a drill press, cutting fluid and go slow. I bought a fancy carbide cutter for the job. First one was slightly off center, the second was perfect. Lined the inside of the cap with cling wrap before pouring in the plaster. If you want I can loan you the cutter I used. Mark

 

[grant_71]

Try to find an electrician with a correct size knockout, will be way cleaner...and easier

 

[No Hay]

Try to find an electrician with a correct size knockout, will be way cleaner...and easier

and faster, and in theory, perfect with a sharp cutter!

 

[EricLar80]

Try to find an electrician with a correct size knockout, will be way cleaner...and easier

Is the hubcap flat in the area he would be cutting?

 

[Scoop]

Hi Justin, I just did this. Use a 3.5 in hole saw. I filled the inside of the hubcap with plaster and a chunk of closet pole to support the metal. Use a drill press, cutting fluid and go slow. I bought a fancy carbide cutter for the job. First one was slightly off center, the second was perfect. Lined the inside of the cap with cling wrap before pouring in the plaster. If you want I can loan you the cutter I used. Mark

Yes, 3 1/2" hole saw works great. Just did one for a spare and my 3 1/2" was dull so I went to Home Depot to get one. They were out and I ended up getting a 3 5/8" bi-metal hole saw. It worked fine as well but 3 1/2" will clear the hub. I bolted in a piece of 1/8" plate for the center pilot hole.