Hole saw vs kockout punch

[rudylyon57]

I have a 1-3/8" Lenox hole saw that I would like to use to cut a number of holes through .040" (1 mm) wall kettles. I see that most of this work is done with punches but I am reluctant to buy one since I have the hole saw. I may also add that 1-3/8" is the ideal size and it seems like the closest punch is 1-1/4".

Has anyone used a hole saw for kettles? If so, are there any pointers for making it work well?

 

[Rockn_M]

I've used bi-metal hole saws for all of my circular holes for building my 3 kettles, and electrical control box. It works fine. Make sure your drill is powerful enough to drill through whatever the material. Also use cutting oil, lots and lots of cutting oil. You also want to make sure you are square before starting to cut the hole or you won't have a perfect circle. I have a few holes that are less than perfect but they aren't leaking and everything fits.

Above all else take your time.

Good Luck!

 

[sandyeggoxj]

No matter how you put holes in stainless you always want to drill slow and with lots of cutting oil. Stainless work hardens very easily.

 

[Homercidal]

A punch is preferred, but I used a step drill and it worked fine. Well, once I got a good drill press anyway. Drilling by hand was not good for my hand drill.

 

[rudylyon57]

Thanks for your inputs gents. I do have a drill press that can be turned down real slow. Gotcha on the liberal use of oil. I may have fun trying to fixture the kettle on the press!

 

[Brettomomyces]

I used the Neiko step bit from amazon, the $14 one. It got me a good 12 holes into my converted kegs before I had to get a new one, and that was my first time using a step bit so I imagine a little "user error" may have worn it down quicker than normal.

 

[rudylyon57]

You can use some abrasive cutoff disks and your air-powered die grinder. I just cut a panel using a jigsaw and it worked fine with a little hand filing of the uncut hole remnant in corners.

http://www.amazon.com/dp/B008S4T1LE/?tag=skimlinks_replacement-20

 

[ajdelange]

A punch always makes a neat, perfectly dimensioned hole with smooth edges rounded from the side opposite the die. The only problem is that they can get pretty expensive and stainless will, eventually, dull them. If the hole edges are concealed beneath the bezels of switches, lamps or controllers it doesn't much matter.