cooper_inc1

this was helpful for me, thanks

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LeViAtHaN_AFO

Just be glad your case isn't like mine. I don't know what the heck kind of steel they used in it, but it absolutely destroyed my hole saws. Bad.. I expected just a standard mild steel sheet metal. Oh no, it feels like a semi high carbon. Even just drilling the pilot hole and screw holes took a lot more effort than expected.

dkev

This is a little more complicated then it needs to be. First off, you don't need a wood guide hole. DO NOT USE HIGH SPEED. You will burn up your hole saw. If you are using a battery drill set it to #2. This is the torque setting. You notice the drill spins much slower. Be very careful if you are using a 18volt drill with this setting. If the saw grabs and your not ready, you can injure your wrist. Apply very little pressure. Let the saw do the work. I also recommend you use painters tape on both sides of the surface. This will reduce burring and damage to a painted surface. Safety glasses are a must. A mask is not. You can use lubricant, it helps with heat build up and preventing the saw from grabbing. I don't use it myself. If it was heavier steel I can see it. And Aluminum is so light you'll drill though it in seconds. Also, don't go from both sides. Your asking for trouble. Once you get your measurement...just get after it and drill the thing out.

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