Re: drilling larger holes in aluminum
 

Annular cutters are fabulous when a precise hole is needed. Our set has seen a lot of action since we bought it a few years back. Makes a great press fit bearing hole if done just right.

Re: drilling larger holes in aluminum
 

We also use annular/Hougen/Blair cutters quite a bit. We have small hole (up to 3/4") and large hole (up to 1-1/2") sets. The only issue with them is the cutter is often very difficult to remove from the arbor after use. We use the little spacer/washer but often it is a a real struggle getting the cutter off. Maybe we are doing something wrong? Does anyone have any tips or tricks to making it easier?

Re: drilling larger holes in aluminum
 

Our set has a small flat on the top away from the cutting edge and we just use a set of channel locks or a wrench to break them loose. Very much important to wait for them to cool down before doing this as that makes it easier too and prevents burns from touching a hot cutter. We typically just grab the arbor in a vise and then break it loose so we can finish removal by hand.

Re: drilling larger holes in aluminum
 

We do a lot of modifying of old parts so it is somewhat often that we have to widen a hole on a mount of some kind. To do this we use a half horsepower dremel with an aluminum cutting bit on it. This when well waxed will cut through aluminum like butter.

Re: drilling larger holes in aluminum
 

Thanks for all the tips and suggestions!

Re: drilling larger holes in aluminum
 

:eek: Y'all are making this way too hard. Get your hands on a set of GreenLee knockouts - a staple in electrical work. They come in various sizes, from 1/2" on up. Typically the larger sets will use a hydraulic puller, and they can cost a chunk of change, but we've used a smaller manual set for years.

Perfect for flange bearings - press fit or slide in with a tiny bit of cleanup. The only hole you have to drill is the 5/8" pilot for the 1/2" bit. If you want to go larger, use the 1/2" first then pick your desired size. Simple. Clean. Effective. Great for lightening holes too.

Safer than a hole saw and cooler than a step bit, they're a lot less messy and don't require lubrication. Properly cared for they should last forever. ::safety::

(Zoro sells a slug splitter with four sizes for $140)

The actual sizes mentioned are "trade sizes" as these dies typically are used for conduit installation. The actual size is slightly larger (1/2" is .875 nominal, e.g.) and can be found via google. Sorry for the confusion.

Put cutting fluid on the threads prior to putting the cutter on the arbor.