Cutting hole in van (1 Viewer)

Jamwitt

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Jun 18, 2012
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:rolleyes:Hi I need to put a 60 mm hole in van for BBQ point with a hole saw but a bit worried as aluminium sandwich construction what type of saw ,I guess it should be a fine toothed saw and where could I get one !
 

Dazzlin

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I just used a standard holesaw.
1 x 20mm pump plug
1 x 70mm gaslow
1 x 90mm bbq point
Just measure twice and go slow.

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Apr 19, 2008
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try this


images
 
Jul 5, 2013
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Buy one from Toolstation or screwfix. Don't bother with the multi-size ones - they are awful and often not deep enough. Instead get the correct size one and an arbour to hold it, Toolstation are cheaper than screwfix, When I was drilling hole through the roof for solar I got a 29mm one and arbour for about £3 from memory.

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Badknee

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When the pilot drill has gone through don't put much pressure on the holesaw as it might bite and the pilot drill may move out of line because the skin is so thin, gently gently. If your really worried practice on a piece of scrap ally.
 
Aug 6, 2013
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Run the saw at full speed but feed it in slowly. The saws are not intended to operate at low speed & to do so will cause it to grab. If you are nervous drill the pilot hole first with a conventional bit then the bit in the holesaw only acts as a guide.
 
Jul 5, 2013
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Since this is a sandwich construction wall the holesaw should not move off of line much once it is through the outer skin. However to make a neat job on both sides I suggest you first drill through one skin and into the sandwich insulation. Then drill from the other side, using the pilot hole that has come through as a guide.

In my experience you will not need much pressure to get through either skin, and certainly not through the insulation. Just push gently with the drill on high speed.

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winchester

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Got the hole saws from travois Perkins and did the electric and bbq point in about an hour fitted, but remember gas must be checked after,DAVE newel did my check
 
Jul 5, 2013
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60mm does not appear to be a standard size. Toolstation will sell you a 57mm or 64mm one, and one of those, with the correct arbour, will cost you between £9 and £10 depending upon what size you go for. On the other hand you can buy from them a set of 7 sizes, including the 64mm one and including the arbour for £5.84!

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pappajohn

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Run the saw at full speed but feed it in slowly. The saws are not intended to operate at low speed & to do so will cause it to grab. If you are nervous drill the pilot hole first with a conventional bit then the bit in the holesaw only acts as a guide.
hole saws are designed to work at an appropriate speed for saw size and material being cut
if you buy quality (starett etc) instead of cheap rubbish there is a leaflet with the saw giving recommended speeds for various materials and saw sizes.
from memory a 100mm saw has a max recommended speed of around 600rpm whereas a 15mm could be as high as 1800rpm.
 

tambo

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Lot of over complicating on this lol

I use these daily .....buy a hole saw mark the hole and drill it .....honestly it isn't hard the aluminium is only 1.2mm thick then polystyrene followed by 4mm board
If it's a new hole saw you'll hardly notice it cutting it will be so quick

You should have had it done by now :p
 

Terry

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Lot of over complicating on this lol

I use these daily .....buy a hole saw mark the hole and drill it .....honestly it isn't hard the aluminium is only 1.2mm thick then polystyrene followed by 4mm board
If it's a new hole saw you'll hardly notice it cutting it will be so quick

You should have had it done by now :p

Most vans are only 0.6 mm :)yours must be posh to be double thickness --mines 1,5 mm ali but on the roof it's now 3 mm :D
terry
 

tambo

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Jun 21, 2014
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Most vans ? Or British vans lol

Mine is 1.2 or 1.5 I never measured it to be honest but had all windows out the other day

Think the roofs thicker as I can walk on it without probs .......but I don't think he's fitting the bbq point in the roof :)

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Aug 6, 2013
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hole saws are designed to work at an appropriate speed for saw size and material being cut
if you buy quality (starett etc) instead of cheap rubbish there is a leaflet with the saw giving recommended speeds for various materials and saw sizes.
from memory a 100mm saw has a max recommended speed of around 600rpm whereas a 15mm could be as high as 1800rpm.
Agreed but the speeds recommended are for continuous cutting - in other words with enough pressure on the saw to maintain continuous cutting and to keep the teeth cool. Doesn't really apply to a millimetre of aluminium - foam (effectively nothing) - 3 or 4mm of plywood.:)
 

pappajohn

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Agreed but the speeds recommended are for continuous cutting - in other words with enough pressure on the saw to maintain continuous cutting and to keep the teeth cool. Doesn't really apply to a millimetre of aluminium - foam (effectively nothing) - 3 or 4mm of plywood.:)
agreed, never thought of that when i replied
 

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