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Old 25 September 2007, 06:46   #1
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Cutting a 135mm hole?? Help!

Does anyone have a hole saw I could borrow? I need to cut two 135mm holes in the console to fit speakers.

Thanks.

Tony
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Old 25 September 2007, 07:23   #2
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Old 25 September 2007, 09:32   #3
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Quote:
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Does anyone have a hole saw I could borrow? I need to cut two 135mm holes in the console to fit speakers.

Thanks.

Tony
Its faily straight forward with a dremmel type tool..
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Old 25 September 2007, 09:34   #4
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Use a Jigsaw for a whole that size it would be just as good.

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Old 25 September 2007, 10:01   #5
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These work well for hole cutting.

Bit like a router, but cheap. should get one at loacl DIY store for about £15.
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Old 25 September 2007, 10:27   #6
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A 5" hole saw would be a) pricey, and b) unwieldly.

Use a jigsaw to cut the size hole you want, plus the diameter of a Dremel arbor, in a piece of plywood. Tape the plywood firmly in place, and use a Dremel tool to cut the hole.

Alternatively, a jigsaw and a 1/4" drill (to start the jigsaw cut) will do, but go slow and try and be accurate.

Sand/file any rough edges (they'll be hidden by the speakers anyway), seal the edges with epoxy, and you're done.

jky
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Old 25 September 2007, 10:51   #7
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A jigsaw is fine if you can get it in the space, you'll be surprised what space restrictions you get when cutting holes.

What's your access like Tony?
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Old 25 September 2007, 11:15   #8
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Excellent! Another hole cutting thread. Anyone doing a console change?
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Old 25 September 2007, 12:09   #9
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A 5" hole saw would be a) pricey, and b) unwieldly

jky
I could not agree more!

135mm equals something just over 5.3 inches. Just to pull such a large hole saw will require a 1/2" or better drill motor and would dislocate your elbow if it hangs up and your access would need to be as good as if you used a jig saw. The template and use of a small router is best if access is limited, if not break out the old jig saw and clean up the edges with a rasp or file.
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Old 25 September 2007, 15:26   #10
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I could not agree more!

.......your access would need to be as good as if you used a jig saw. The template and use of a small router is best if access is limited, .....
I could not disagree more!
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Old 25 September 2007, 16:03   #11
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I could not disagree more!
Isn't that how you did yours then i guess a nice big 1/2 " 2000w would be best with a 1" bit.
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Old 25 September 2007, 16:28   #12
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My preferred method for cutting a hole of this size is to chain drill out the circumference with a 6mm drill. Cut out the remaing disc with a junior hacksaw blade and finish off with a half round file if required.
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Old 25 September 2007, 17:45   #13
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Isn't that how you did yours then i guess a nice big 1/2 " 2000w would be best with a 1" bit.
Nah - I was disagreeing with Tomas's statement that a holesaw would require as much access space as a router or jigsaw, which it clearly doesn't.

I haven't fitted speakers. With my crew, I wouldn't hear anything from them
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Old 26 September 2007, 06:59   #14
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Nah - I was disagreeing with Tomas's statement that a holesaw would require as much access space as a router or jigsaw, which it clearly doesn't.

Ah the details. On second thought, a jig saw would take more lateral space but a small router would not. I consider a hole saw that large however to be a tunnel boring machine, not a hand tool.
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Old 26 September 2007, 16:35   #15
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.... a jig saw would take more lateral space but a small router would not.....
Oh yes it would

The base of the router would protrude much further past the cutting edge of the bit than in the case of a holesaw.
Take eg a small router with a 80mm diameter base. This would track a circle diameter of 40 + 135 + 40 = 215mm, whereas a 135mm holesaw only needs 135mm. Simple
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Old 26 September 2007, 17:15   #16
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i use routers for a living and unless it was on a flat surface and horizontal with a decent template I wouldn't go near my consul with one .

I think Yoyo's method is by far the best and cheapest, time isn't the issue here.
Maybe a drill with flapper wheel to smooth it out if you are lazy but that can still slip .
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Old 26 September 2007, 19:57   #17
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Hole saw is the best or a small Angle grinder if you are good enuff, If not use a jigsaw with masking tape on the sole plate to avoid scratching the Gell
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Old 27 September 2007, 00:06   #18
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Hi,
I would mark the 135 circle with black marker then use a variety of hole saws starting with the biggest i have working to smaller then chain drill ....not to difficult in grp ........dremels are also underated tools for this, but can be a pain to control and can quickly grab and run across a nice piece of fibreglass....routers can be a bit cumbersome especially if its not on the flat and would be difficult to control and follow the line due to its high speed waste. their structure also limits the controllers vision to follow lines...most router users either use templates or bearing guided cuters ...

135mm is quite a tight contour for a jigsaw ...do-able.. but easier methods also depends on blade as grp splits quite bad ...metal blades seem to work for me on grp.
if its speakers then they tend to have a lip all round them so a slightly untidy hole is covered anyway.

cheers

Ian
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Old 27 September 2007, 01:29   #19
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Hi,
135mm is quite a tight contour for a jigsaw ...do-able.. but easier methods also depends on blade as grp splits quite bad ...metal blades seem to work for me on grp.
if its speakers then they tend to have a lip all round them so a slightly untidy hole is covered anyway.

cheers

Ian
getting the right blade alwasy helps http://www.axminster.co.uk/product-B...01AO-23410.htm
looks like it would be up for the job.
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Old 27 September 2007, 03:47   #20
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18 posts on how to cut a hole!!! this is the only way to do it, draw a X roughly where you want the hole and hit it with a 2lb lump hammer then duct tape the speaker over the hole.
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