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Old 10-01-2012, 03:35 PM   #1001
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I'd like to do this with a one inch half coupler on a keg for a heating element. What would you guys use to cut a hole that big. Im guessing it will be about an inch and a half. Using an inch and a half hole saw in a curved stainless keg sounds like it would go badly. I also don't want to buy an expensive greenlee punch set. Has anyone successfully used a big holesaw with a hand drill on an interrupted cut like this.

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Old 10-01-2012, 03:46 PM   #1002
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I did mine with a step bit, and ended up having to take the die grinder in after to open it up a little. For the element I really recommend using boobym's welding spuds.

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Old 10-01-2012, 03:48 PM   #1003
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does anyone have a video or pictures if using the spud? Also where did you find a step bit that big?

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Old 10-01-2012, 03:56 PM   #1004
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forget the step bit. use a hole saw. much quicker and cheaper.

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Old 10-01-2012, 03:59 PM   #1005
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well I already have a hole that was made via a greenle punch so I could use a weldless. I would like to make it welded so it will need to be expanded to fit the spud and I imagine using a hole saw to enlarge a hole will be difficult.

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Old 10-01-2012, 04:17 PM   #1006
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Not sure if there are any step bits that big, I used a punch - I belive it was 1-5/8"

would your current hole be too close in size to punch a bigger one?

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Old 10-01-2012, 04:31 PM   #1007
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A bigger punch would probably work. The problem is I am grad student on a budget! Dustbow do you still have the punch and could measure the diameter and that way I can check to see if it would work before I spend forever looking for a deal I can afford.

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Old 10-01-2012, 04:51 PM   #1008
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Quote:
Originally Posted by ekjohns View Post
well I already have a hole that was made via a greenle punch so I could use a weldless. I would like to make it welded so it will need to be expanded to fit the spud and I imagine using a hole saw to enlarge a hole will be difficult.
does it have to be in that same spot? could you just solder in a coupler or half coupler and use that for something else? thermometer/sight glass/thermocouple/whirlpool port/herms coil/etc ?
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Old 10-01-2012, 04:51 PM   #1009
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Quote:
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forget the step bit. use a hole saw. much quicker and cheaper.
Have you personally use a hole saw to drill a keg? Three things that are bad for hole saws are stainless, interrupted cuts (curved surfaces) and sheet metal. I'm just interested if anyone has done this without breaking their wrist or burning up the saw half way through.
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Old 10-01-2012, 04:54 PM   #1010
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i did my first set of holes with the step bit. seemed to burn them out, certain sizes in the bit would get too hot and get dull. you're basically drilling 8 holes to get to the size you need.

i did all my new HLT and BK electric stuff with 2 hole saws, one for the heating element and one for the 1/2" couplers. faster and easier than the step bit, no question. left the edge just a little rougher than the step bit, but i went and cleaned it up with a file or grinding stone and all is well.

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