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Thinking about putting a window in my side panel - Page 2

post #11 of 26
For my cutting I used a drill bit in the corners and then went round with the jigsaw, then fitted C-channel
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post #12 of 26
Thread Starter 
this is the look im going for with the bolt method:

concept


example (ignore design and fan)


is it possible to get edges as smooth as that with jigsaw + file?
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post #13 of 26
Quote:
Originally Posted by Microsis View Post
is it possible to get edges as smooth as that with jigsaw + file?
Yes

To make the edges smooth you could always go round the cut-out with wire wool after you have filled it back.
    
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post #14 of 26
Thread Starter 
Quote:
Originally Posted by marcus000 View Post
Yes

To make the edges smooth you could always go round the cut-out with wire wool after you have filled it back.
does the wire wool act as sand paper?
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post #15 of 26
if you want a radius in the corners use a 2 inch hole saw,jig saw with a guide is the best way to cut ,i use my table saw i only recommend for the experienced,if you never did this before i wouldnt then.
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post #16 of 26
Quote:
Originally Posted by Microsis View Post
does the wire wool act as sand paper?
Kinda, wire wool is finer than sand paper though.

File it down, sand it with some wet/dry if you like and then wire wool it.
You can get it as smooth as a baby's bum!
    
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post #17 of 26
thats how I plan to cut my window, holesaw for the 4 corners, then the dremel jig for the straight lines, then a bit of filing, topped off with c-channel. I am using channel because I like how it looks and black trim is part of the overall color scheme/color accent of the project.

Microsis, if you use hole saws get "bi-metal" type. Home depot sells kits and loose assorted sizes. I have about ten sizes mixed between a smaller size kit and loose for the larger fan sizes. Also, you may need a pilot bit and/or an arbor if you get them loose. kits will usually have the part included.
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post #18 of 26
Thread Starter 
Quote:
Originally Posted by CattleRustler View Post
Microsis, if you use hole saws get "bi-metal" type. Home depot sells kits and loose assorted sizes. I have about ten sizes mixed between a smaller size kit and loose for the larger fan sizes. Also, you may need a pilot bit and/or an arbor if you get them loose. kits will usually have the part included.
just got back from Lowes, and saw that 99% of the hole saws they have are designed for wood. Is it a bad idea to use those? Also what does "bi-metal" mean?

Also what's a pilot bit/arbor?

thanks again
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post #19 of 26
no, dont use wood hole saws for metal case

bi-metal is the type of hole saw, simply put, its for metal

arbors and pilot bits are sort of interchangeable terms. Smaller hole saws use a pilot bit which is simply a drill bit that the holesaw can lock onto. Some holesaw kits come with a simple pilot bit or a collared pilot, where the lock mechanism is part of the bit instead of the holesaw itself. Then there's arbors which act as a pilot bit but also have an adjustable locking fly/wing thing on the collar, which extends outward from the pilot and locks into the holesaw in separate holes. It acts as a stablizer and a torque mechanism for the larger holesaws.
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post #20 of 26
Thread Starter 
Quote:
Originally Posted by CattleRustler View Post
no, dont use wood hole saws for metal case

bi-metal is the type of hole saw, simply put, its for metal

arbors and pilot bits are sort of interchangeable terms. Smaller hole saws use a pilot bit which is simply a drill bit that the holesaw can lock onto. Some holesaw kits come with a simple pilot bit or a collared pilot, where the lock mechanism is part of the bit instead of the holesaw itself. Then there's arbors which act as a pilot bit but also have an adjustable locking fly/wing thing on the collar, which extends outward from the pilot and locks into the holesaw in separate holes. It acts as a stablizer and a torque mechanism for the larger holesaws.
damn you really know how to earn your reps dont you? lol

anyway, if i get say a 2" hole saw, would you recommend i get one with a pilot bit then?
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