Cutting Large Holes In Sheet Metal

Be that as it may here is a neat idea from flyboy accessories for cutting larger holes in sheet metal.

Cutting large holes in sheet metal. It is common practice to use a self starting step bit to form the. Depending on the tools you have you ll now need to punch or drill a hole where the indentation has been made to produce an accurate hole in your sheet metal. Tap your hammer to leave an indentation on the sheet metal. For this step you ll need a compass ink and a center punch.

Use a scrap of plywood as a backer for the hole saw s pilot bit and to protect your work surface. It s meant for creating lightening holes of the type seen when building aircraft or maybe just toolboxes and furniture that are built like wwii fighter planes. I ve messed with trepanning tools abrasive wheels hole saws and all manner of other stuff for cutting large holes in sheet metal. The fracture region starts at the end of the burnish region and occupies most of the rest of the thickness of the cut with exception to the burr.

For large holes a hole saw gets the job done cleanly and quickly. Like twist bits hole saws chuck right into your drill and will cut through thin gauge sheet metals like aluminum and steel. In response to a question about h. Don t say that you were thinking of holding that metal sheet with bare hands.

How to cut a round hole in sheet metal. Place your sheet metal on your steel block and position your centre punch at a central point in your cut out design. Follow few steps step 1. In a well designed sheet metal cutting process the cracks should meet each other and form a continuous break.

Step bits can be used to make even larger holes typically 1 3 8 inch wide or smaller in sheet metal but do require pilot holes.