hole saw for aluminium heat shield

sarabande

sarabande

Well-Known Member
Joined
6 May 2005
Messages
36,182
Visit site
I need to drill several holes in a 2mm sheet of aluminium (not hardened alloy), and have no experience of a brand of good metal hole saws.

Recommendations for make and supplier will be appreciated. TIA
 
I would use a Bi metal hols saw
F0466794-01.jpg


But a cheep chinese one would cut 2 holes in soft aluminium.
 
Pretty well any holesaw except the rubbish cheap multi size ones will cut though 2mm aluminium. The method is however important when cutting thin sheet material. You need to get a piece of scrap plywood and put the sheet on that. Drill through both untill the aluminium is completely cut through. Ideally do in on your nice drilling machine.
 
sarabande said:
I need to drill several holes in a 2mm sheet of aluminium (not hardened alloy), and have no experience of a brand of good metal hole saws.

Recommendations for make and supplier will be appreciated. TIA
Click to expand...
What size holes? If you’re calling this way (as you suggested you might be a couple of weeks ago), I’ve got a whole range of holesaws and arbors. Help yourself so long as I can have them back when you’re done.
 
Using a holesaw with big teeth on thin ali may not end well!
What size?
You might do better looking for a punch and die, or using a fly-cutter kind of hole cutter?
 
TernVI said:
Using a holesaw with big teeth on thin ali may not end well!
What size?
You might do better looking for a punch and die, or using a fly-cutter kind of hole cutter?
Click to expand...

Big teeth when cutting thin metal is only a problem when cutting across the thickness not when cutting through the thickness.

Bigger teeth is in fact better when cutting soft metal as it reduces the metal buildup i the teeth

The general rule is to have 3 teeth in contact with the material for easy cutting the OP would mostly have all the teeth in contact until the breakthrough. This i why a bench drill if the best machine rather than a hand drill but with care a hand drill will do the job.
 
Rogershaw said:
Big teeth when cutting thin metal is only a problem when cutting across the thickness not when cutting through the thickness.

Bigger teeth is in fact better when cutting soft metal as it reduces the metal buildup i the teeth

The general rule is to have 3 teeth in contact with the material for easy cutting the OP would mostly have all the teeth in contact until the breakthrough. This i why a bench drill if the best machine rather than a hand drill but with care a hand drill will do the job.
Click to expand...

I drill various sheet material to fit items. I have not too much of a problem with teeth clogging. Hike saw with arbor is probably a cheaper more readily available option for the o.p.
 
davidpbo said:
I drill various sheet material to fit items. I have not too much of a problem with teeth clogging. Hike saw with arbor is probably a cheaper more readily available option for the o.p.
Click to expand...

I don't because I use the correct tooth pitch for the job concerned.

Must admit I don't use much aluminium I use a lot more stainless steel and it too much heat and not enough lubricant/coolant
 
Screwfix have a range of holesaws, and both Starrett and Bosch are good quality. I have some of both, and each does the job. well. I do use tool lubricant, as I have some, and it helps.

What size of 'oles are you looking to cut? I may have the right thing.... even a 165mm core drill - 'The Monster'.....
 
penberth3 said:
All the hole saws I've seen recently have variable pitch.
Click to expand...

I really was talking about when edge cutting of thin metal.

Yes variable pitch hole saws do have an advantage of less chatter and possible can cut deeper with out having to clean the chips away.

Local suppliers tend to only stock the cheaper of a particular type.
 
zoidberg said:
Screwfix have a range of holesaws, and both Starrett and Bosch are good quality. I have some of both, and each does the job. well. I do use tool lubricant, as I have some, and it helps.

What size of 'oles are you looking to cut? I may have the right thing.... even a 165mm core drill - 'The Monster'.....
Click to expand...
It's unlikely that you will need a cutting lubricant but use parafin if you do.
 
I am sitting here all ears and eyes, having spent a large part of yesterday and today dealing with gremnils in the hydro electric station, and tree that has fallen across the carriageway.

Diaries to collect books, borrow hole saws and other essential journeys are all in abeyance for a week or two.

However, my knowledge of the best way to perforate aluminium has increased considerably over the last couple of days, and as soon as real life resumes, I shall be on the road. Thanks everyone.

Punching holes seems to be a quicker way, and I know the local fabrication shop has such a machine. Super-neatness of finished edges is not part of the specification.
 
Tim, shame you didn't mention the need for hole cutters when you were here on Wednesday, I have a good selection of Starrett hole cutters from 13mm up to about 140mm. You would have been welcome to rummage about to see if there was the size you need.
 
sarabande said:
I am sitting here all ears and eyes, having spent a large part of yesterday and today dealing with gremnils in the hydro electric station, and tree that has fallen across the carriageway.

Diaries to collect books, borrow hole saws and other essential journeys are all in abeyance for a week or two.

However, my knowledge of the best way to perforate aluminium has increased considerably over the last couple of days, and as soon as real life resumes, I shall be on the road. Thanks everyone.

Punching holes seems to be a quicker way, and I know the local fabrication shop has such a machine. Super-neatness of finished edges is not part of the specification.
Click to expand...
Sorry to hear of your trials and tribulations, but I'm still all agog to know what size holes you need to cut?
 
You must log in or register to reply here.

Share this page

Top