Originally Posted by tkone
cool. that being said, if i'm drilling a hole for a 1" water heater element, should i drill a 1" hole? or a 15/16 hole and dremel it out until the element just fits to make it more water-tight?
Unless you have a jig you can't get it round enough with a dremel. And you can't drill a pilot hole for the larger one. The OD of the threads on the element (at least the one in front of me) is 1.285" so even 1 1/4 won't quite do but it might be a reasonable start.
The machine shop that does our work advises to go slow on Stainless when drilling and use lots of pressure, take lots of breaks to let it cool and use cutting oil. You might try the 1 5/16 of these:http://www.hougen.com/cutters/sheetmetal/Holcutters.html
Edit: That's one and 5/16 not 15/16