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Using a metal hole saw on aluminum

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mccoy178:
I want to use a 1 3/16" metal hole saw to cut my holes in my cp that has the artwork attached.  I have an industrial size drill press at my disposal, so with that said, do you guys see any issue with using this method?  I will be installing translucent leaf switches, thus the slightly larger hole size.  Will jumping around occur?  I don't see how it would be that great, but thought I would ask first.  The overlay isn't cheap. :dizzy:

TOK:
I think the heat would be a bigger problem for the overlay. I think I would use a metal punch to do this... Not sure if thats the correct name. They're the things where you drill a small pilot hole and attach the two cutting sides with a bolt. When the bolt is tightened it cuts the metal.

We use them to cut the external sheet metal on our work vans to route wires. Makes very clean holes and doesn't burn the paint.

Minwah:
I second the hole punch, they work great.

mccoy178:
Good point.  The biggest problem I have seen with those is finding the right size.  I'll put some effort into it today. 

Ken Layton:
Yes, a Greenlee brand "knockout punch" (a.k.a. "chassis" punch) would be a choice in your application. If you were to use a hole saw on aluminum, the aluminum would quickly clog the hole saw teeth. You should use cutting oil on aluminum anyway, but the cutting oil would get underneath the overlay of yours and ruin the adheisive.

Go to Home Depot in the electrical section and buy a Greenlee knockout punch for 3/4" electrical conduit. It will punch the correct hole for game buttons.

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