Difficulty making 1.5" hole

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BitterSipper

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I can't seem to find a way to make a ~1.5" hole. The step bits only go up to 1-3/8 which is just a hair too small. and the punches don't really work.

Last time I cut the 1-3/8th then used a conical piece of metal to enlarge the whole with a press, but it didn't turn out great and this time I just want a nice clean 1.5" hole.

Anyone have a good method/tool?
 
Two options.

a) take it to a welding shop. They'll get a hole in there, sometimes for free.

b) rent one of these.

RB45-lg.jpg


Like buttah.
 
BitterSipper said:
I can't seem to find a way to make a ~1.5" hole. The step bits only go up to 1-3/8 which is just a hair too small. and the punches don't really work.

Last time I cut the 1-3/8th then used a conical piece of metal to enlarge the whole with a press, but it didn't turn out great and this time I just want a nice clean 1.5" hole.

Anyone have a good method/tool?
Click to expand...

Do you want to use a weldless fitting in that hole, or are you going to weld/solder a fitting in it?
 
BitterSipper said:
Have you actually tried that on a pot? Because last time I did it did not work well at all.


Yea I thought about enlarging the hole something like that, but it's hard to keep it perfectly round.
Click to expand...

I can understand the hole bit not working well, as they are designed for wood and composites. Certainly not thin metal, what with those huge teeth.

You need to go from 1-3/8" to 1-1/2", which means grinding 1/16" all around the circumference of the hole. It's not as hard as you'd think, but you need a steady hand.

I did it on a keggle, when all I had was a step bit with a max. 3/4" diameter. I wanted to enlarge the hole to 7/8" to accept a weldless valve. Using a drafter's circle template and scratch awl, I marked a circle of the final diameter, then drilled with the step bit. Next, I carefully used the Dremel until I reached the circle. It took some time, and it's LOUD (wear ear plugs). The key is to be very patient and not grind too aggressively. But I was able to make it very close to perfectly round. I then used the same Dremel bit to remove the burrs and I was in business.
 
TimmyWit said:
I missed what you were drilling in your first post. A 38mm step bit does exist but it looks like it won't be cheap:

http://www.ebay.com/itm/like/400759563758?lpid=82&chn=ps
Click to expand...

A thicker than normal SS pot, thicker than the concord or bayou pots.

jsprinceiii said:
Flaring the hole would be the easiest.
However..
Here is a 1-1/2" radio punch.. it is tougher to use, since you already have a hole close in diameter..

http://www.ebay.com/itm/Greenlee-1-...292?pt=LH_DefaultDomain_0&hash=item19f5ca396c

(Ebay search: greenlee radio punch 1-1/2)
Click to expand...

I didn't make the hole yet, I was hoping to find a better way first. I don't remember why I didn't like the punches last time, It was either they weren't strong enough, or I didn't have the right size. They typically are not rated for this thick of metal though. Have you had good luck with them in SS?
 
I find the opposite is true. Punches don't work very well on thinner pots because there's a thin gap between the punch and die that can pull the metal in and get all jammed up. You can get a 1.5" punch, but the one holesaw that eats stainless for lunch is the http://www.amazon.com/dp/B00125F8YU/?tag=skimlinks_replacement-20 but you also need the arbor and it's not cheap.

If you're having a 1.5" TC flange welded in, you may also try drilling a 1-3/8" and pulling the 1.5 into the hole. The hardest part is finding an appropriate sized backing die, which is typically 1/8" larger ID.
 
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BitterSipper said:
A thicker than normal SS pot, thicker than the concord or bayou pots.



I didn't make the hole yet, I was hoping to find a better way first. I don't remember why I didn't like the punches last time, It was either they weren't strong enough, or I didn't have the right size. They typically are not rated for this thick of metal though. Have you had good luck with them in SS?
Click to expand...

What type of Pot?

We punched Blichmann(approx. 1.2mm) andMegaPot 1.2 (1mm), like cutting butter with a hot knife. Keep the cutter lubricated.
These dies should be good for 14 guage or approx 2mm
 
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jsprinceiii said:
EZCyclone,
Max size is 1-3/8.
BitterSipper is looking for 1-1/2
Click to expand...

Interesting, the image I have in the email, shows it goes to 1 1/2", but when you go to the page and look at the image there, it shows 1 3/8". Fair enough, my bad.
 
I have an Irwin that goes to 1 5/8", got it at Ace Hardware, even though I hate that place.
 
jsprinceiii said:
What type of Pot?

We punched Blichmann(approx. 1.2mm) andMegaPot 1.2 (1mm), like cutting butter with a hot knife. Keep the cutter lubricated.
These dies should be good for 14 guage or approx 2mm
Click to expand...

Doesn't have a brand really, it's closer to 2mm.

I might give a punch a try then. Does it typically punch a hole the same size as the die, or does it over/under size? Also, does it distort the shape of the pot around the hole or punch clean?
 
BitterSipper said:
Doesn't have a brand really, it's closer to 2mm.

I might give a punch a try then. Does it typically punch a hole the same size as the die, or does it over/under size? Also, does it distort the shape of the pot around the hole or punch clean?
Click to expand...

Radio Punch dies are the same size as stamped. Conduit dies are the size of the pipe. Use the radio punches.

Clean hole..
I have been using Greenlee punches for over 35 years, they work wonderfully.
I have cut 12 Guage steel (mild steel), and 14 guage Stainless.. Key is to keep the die lubricated. WD40 will work, if you have cutting oil available, use it.

Also..
Bobby has a cool video, actually using one, starting around 8 minutes in..
(Nice Job Bobby!!)

 
Last edited by a moderator:
jsprinceiii said:
Radio Punch dies are the same size as stamped. Conduit dies are the size of the pipe. Use the radio punches.
Click to expand...

I meant more, when it says 1.5 does it make a 1.5" hole or more like a 1 3/8 or 1 5/8. Welders always want a snug fit.
 
A 1.5" radio punch will punch a 1.5" hole.
a 1.5" conduit punch will punch a 1.95" hole

Check with your welder, in most cases they also have the tools to fabricate the hole.
 
I'd take it to someone to cut the hole with a plasma torch and have them weld the fitting at the same time. Done.
 
jsprinceiii said:
A 1.5" radio punch will punch a 1.5" hole.
a 1.5" conduit punch will punch a 1.95" hole
Click to expand...

Yes but I'm asking does a punch that is supposed to punch a 1.5" hole, punch a hole that's very close or does it end up over or under sized. For instance hole saws always seem to end up over-sized.
 
Again --- unless you're planning to do your own welding, wouldn't it make sense to take it to someone who can cut the hole AND weld it? Just sayin'.
 
Pete_WNY said:
Again --- unless you're planning to do your own welding, wouldn't it make sense to take it to someone who can cut the hole AND weld it? Just sayin'.
Click to expand...

I'm sure they can, I just prefer to do as much as I can myself. Less chance of miscommunication, and I would rather have to hold myself accountable for a mistake than someone else.
 
Bobby_M said:
I find the opposite is true. Punches don't work very well on thinner pots because there's a thin gap between the punch and die that can pull the metal in and get all jammed up. You can get a 1.5" punch, but the one holesaw that eats stainless for lunch is the http://www.amazon.com/dp/B00125F8YU/?tag=skimlinks_replacement-20 but you also need the arbor and it's not cheap.

If you're having a 1.5" TC flange welded in, you may also try drilling a 1-3/8" and pulling the 1.5 into the hole. The hardest part is finding an appropriate sized backing die, which is typically 1/8" larger ID.
Click to expand...

Concord was selling the carbide tipped hole saws ans I wondered how they were working and then I started looking at similar ones available on ebay.

http://www.ebay.com/itm/New-Carbide...210?pt=US_Hand_Tools&var=&hash=item2ec8fa9212

When are you going to have something similar up on BrewHardware?:rockin:
 
Last edited by a moderator:

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