drilling larger holes in aluminum

[MrBasse]

Originally Posted by dradel

Personally I favor these for up to 3/4" they do come larger as well

https://www.amazon.com/gp/aw/d/B0082...ScL&ref=plSrch

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.

[ChuckDickerson]

Originally Posted by MrBasse

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.

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?

[MrBasse]

Originally Posted by ChuckDickerson

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?

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.

[MonroeM]

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.

[James3245]

Thanks for all the tips and suggestions!

[SparkyMark]

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.

(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.

[dradel]

Originally Posted by ChuckDickerson

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?

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