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  1. #1
    Join Date
    Jan 2013
    Posts
    1

    Default Need 4 1/2" hole in Aluminum ??

    Need to cut 4 1/2" hole in 1/4" Aluminum backing plate for fighting chair.
    Plate is secured to underside of floor deck of boat so it will be a 1/2" drill, not a drill press.
    i only need to make 1 hole. Will a 4 1/2" Milwaukee hole saw work on Aluminum ?
    or do I need a specialized bit ??
    Thanks Ed

  2. #2
    Join Date
    Apr 2009
    Location
    Upstate SC
    Posts
    139

    Default

    Lacking proper tools, I'd just use a saber saw and a good metal blade for just one hole.
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  3. #3
    Join Date
    Apr 2012
    Location
    Western Pa.
    Posts
    219

    Default Need 4 1/2" hole in Aluminum ??

    Alm is soft, should work for one hole.

  4. #4
    Join Date
    May 2012
    Posts
    27

    Default

    I work on boats all day the only thing i find that will cut aluminum easy is a plasma. I do this all day and found that it is the right way to do this. Good luck

  5. #5
    Join Date
    Feb 2012
    Location
    Wa
    Posts
    544

    Default

    Just use the hole saw. I hole saw 1/4" steel all the time. Aluminum will be cake.

  6. #6
    Join Date
    May 2011
    Location
    Bossier Parish La.
    Posts
    547

    Default

    Quote Originally Posted by Cgotto6 View Post
    Just use the hole saw. I hole saw 1/4" steel all the time. Aluminum will be cake.
    The 4.5" Milwaukee hole saw will do the job just fine, and alot cheaper than buying/renting a plasma torch to make only one hole. A jigsaw with a metal cutting blade will do it too, if it doesn't have to be perfectly round, just close enough to round.

  7. #7
    Join Date
    Oct 2006
    Location
    Illinois
    Posts
    597

    Default

    I would use the hole saw too. If you want to keep the hole saw from wandering, drill the 4 1/2'' hole in a piece of plywood that will fit in your hole location. Cut the plywood so it is large enough to stand on. This will work as a guide and should work out well.

  8. #8
    Join Date
    Sep 2005
    Location
    northern NJ
    Posts
    1,840

    Default

    Use something to help wash away the chips. Water soluble oil, Wd40, etc. even just plain water will help keep the hole saw from loading up. A drill with an extra handle is prefered so when it catches less chance of hurting your wrist.
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  9. #9
    Join Date
    Jul 2010
    Location
    Salem, NJ
    Posts
    271

    Default

    Hole saw

    and lube the aluminum, you can even use tapping fluid, it will bind to the chips and remove them faster. Slow speed, you don't want to burn up your $5 hole saw

  10. #10
    Join Date
    Oct 2007
    Location
    Cave Creek Az
    Posts
    970

    Default

    Ditto the hole saw. A little lube and it will take less time than reading this thread.

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