Cutting hole in van

Discussion in 'Motorhome Chat' started by Jamwitt, Aug 30, 2014.

  1. Jamwitt

    Jamwitt Funster Life Member

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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 !
     
  2. vwalan

    vwalan Funster

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    good builders merchant .
     
  3. Dazzlin

    Dazzlin Funster Life Member

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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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  4. B-well

    B-well Funster

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    try this


    [​IMG]
     
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  5. grasscutter

    grasscutter Funster Life Member

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    I also used a standard hole saw. The walls are so thin it goes through easily.
    As above, measure twice and cut once.(y)
     
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  6. Jamwitt

    Jamwitt Funster Life Member

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    Was your grip or Ali skinned!
     
  7. Jamwitt

    Jamwitt Funster Life Member

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    Whoops grp
     
  8. tambo

    tambo Read Only Funster

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    Standard hole saw will be fine ....The aluminium is really thin just go slow let the saw do the work ....
     
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  9. peterc10

    peterc10 Funster

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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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  10. Badknee

    Badknee Funster

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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.
     
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  11. tonyidle

    tonyidle Funster

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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.
     
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  12. peterc10

    peterc10 Funster

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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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  13. SuperMike

    SuperMike Read Only Funster

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    Saws, smaws, use a sharp chisel and a 4lb hammer. Big bunch of girls. :sneaky:
     
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  14. winchester

    winchester Read Only Funster

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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
     
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  15. peterc10

    peterc10 Funster

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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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  16. pappajohn

    pappajohn Funster Life Member

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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.
     
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  17. pappajohn

    pappajohn Funster Life Member

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    in fact, forget the chisel Mike.....the 4lb lump hammer will make a hole quite easily on its own.
     
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  18. SuperMike

    SuperMike Read Only Funster

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    True, I stand corrected. :notworthy2:
     
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  19. tambo

    tambo Read Only Funster

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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
     
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  20. Terry

    Terry Funster

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    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
     
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