Noob question -- 2-1/16" holes in .25" aluminum?

[mjdwyer23]

Hi Folks-
I am looking to make a plate out of .25" aluminum sheet to hold my 2-1/16" autometer gauges. What's the best way of going about making these holes? Hole saw? Thanks!

[oestek]

Check out the Blair holcutter saws... they are awesome for cutting perfect circles.

[astroracer]

Regular holesaws will work fine if you make a guide block first. Use the hole saw to drill a hole in a piece of scrap plywood. Clamp this piece on your blank and run the holesaw down through it rather then using the drill bit as a guide. Keeps the saw from wandering.
If you use a 2" holesaw it will come out real close to 2.06. A little work with a drum sander should get you there.
MAS

[Holohan]

Use the Blair or Hougen cutters along with Aluminum Tap Magic cutting fluid or WD-40 works well also

[ammoyer]

Did you really mean 0.25" aluminum or 0.025"?

1/4" plate seems a little overkill for a gauge panel, but what do I know? I agree with all that was posted above. Good advice.

Adam Moyer

[mjdwyer23]

I'm using what I can get from the scrap bin at work. Today I found a piece of 1/8" aluminum that is about 16"x10". The panel I'd like to make is 4"x14" and will house three 2-1/16" gauges and a few switches.