Best way to drill/put 2 5/16" holes in sheet metal?

[Rileys68Camaro]

I'm looking at trying to make a guage panel, depending on what it will cost. If it's spendy, I'll buy an Autometer.

So, how would I make these large holes in a piece of sheetmetal? Can I use a hole saw on my drill?

Would it be that expensive to have a shop put a 90* or so bend in it and drill four holes?

Thanks!

[Camaro Zach]

Hole saws work well just make sure they are the ones made for cutting metal. you can also use a jig saw if you wanted but it might take a while.

What gauge sheetmetal are you using? you should be able to bend it by yourself using some wood and C-clamps

[Rileys68Camaro]

I was planning to use 16-18 guage sheet metel and paint it.

Just not sure on the bend.

[CAMAROBOY69]

Make a gauge panel? I cant even imagine doing that. All jokes aside. I used a hole saw for my first designs. A 4" hole saw and a 2" hole saw. Make sure the hole saw doesnt walk or your screwed. Your holes will be off centered and will be noticable. Then I used a drill and a couple different size grinding bits to make the holes big enough.

[parsonsj]

Go have a look at Mittler Bros. They sell sheet metal punches for large holes and sell a punch specifically for 2 5/8 gauge holes.
jp

[Camaro Zach]

this method works quite well. i used it untill i bought my own brake

[boodlefoof]

Speaking from the experience I had with my own guage panel project, I'd go with lighter than 16 ga. steel. It is kind of overkill and just tougher to get a nice, properly placed, bend in... If I had it to do again, I'd use 20 ga.

Ditto the slightly under-sized hole saw and then hogging it out with a grinder.

[harshman]

Try aluminiuinuminum. It is softer and much easier to form. You can also make it brushed aluminum by spraying it with WD40 and using some fine sand paper. I did that with my 3 gauge cluster and mounted it where the radio goes.

[HHStang]

Hole saw works fine. get it at least an 1/8th INCH smaller than hole wanted though.

[MuscleRodz]

Circle cutter in a drill press is another way and make sure the metal is secured well. Aluminum is great for a project like that. I prefer hole punches too but can be a bit pricey for one time use. I have had several made and bought a few.

Mike

[Rileys68Camaro]

I got a quote for $70 for 3/16th aluminum, and $54 for sheet metel.

I didn't think, but I really only need like 1/8th inch aluminum.

Two Auto Meter panels would be only $24 plus shipping.

[Camaro Zach]

whoa no no you dont need 3/16 or even 1/8

you need something like 16 or 18ga. aluminum and 18-20ga. steel

i'd be happy to bend, drill holes, and supply metal for $24 plus shipping if you want lol

[MuscleRodz]

.050 would be plenty in aluminum

Mike

[Rileys68Camaro]

Yeah, wasn't thinking. Really don't need it that thick.

[David Pozzi]

Find a heating system shop, they have sheet metal brakes and hole punches. Lay out where you want the holes and the bend, Get a piece of welding rod or coat hanger and bend it to the angle you want the sheet metal bent to, use it as a template.

Electrical contractors and stereo installers have punches too but usually in conduit sizes.
You can have the holes punched as close as they can get, then file them larger to fit. Use a protractor to mark the hole dia before they punch it.

If you use a hole saw, drill from the backside to reduce scratches, or put masking tape on the front side before you drill, swarf from the saw will cause the scratches.