Rigging-Holes in aluminum?

[Trophysport]

I am planning on installing 2" round amber lights in my boat, and the places I want to put them are aluminum covered with carpet. What is the best method to cut a 2" hole in this?

Also, I plan on installing rear speakers in the area where there are existing 4" cutouts. The speakers require 4 1/8". Any suggestions on making the existing cutout a little bit larger?

Any suggestions will be appreciated!

Trophysport

[Marble Eyes]

For the Light holes, Go buy a good Bi-metal Hole Saw. They make them in that size. But you will need a decent drill to turn it. Use a punch to mark your spot in the Aluminum then put the bad boy to work.

Let the drill do the work and don't force it.


I would probably try a Jig saw for the speaker holes. I don't really know, but that would be my first thought.

[davey crockett]

I would use a Dremel tool. Either buy or borrow one. It is the car audio installers best friend. It will work wonders for your boat as well.

[FishGuy]

I second DC's suggestion. I have used mine on aluminium without problems - just make sure to use gentle, even pressure and do not force the tool, otherwise you my end up with a hole that is not perfectly round.

Hope this helps. Dan

[mac]

You need to snag proof the carpet first. If it is nylon or a synthetic a soldering iron works well or perhaps someone else has a suggestion.

[Trophysport]

Thanks for the responses. I figure I have one chance to do it right, so the advice is appreciated.

p.s. Sorry about posting on the General board, next time I will post a question like this on the Boat & Motor board.

[WalleyeGuy]

I've done this a lot of times. After you pattern the hole, cut the carpet with a box cutter. Use a two pencils with a piece of string tied between them. Make sure point to point is 1/2 the diameter, and then draw your circle. Use the bimetal hole saw for the small holes. Use a Saber Saw with a fine tooth blade to cut the large holes. Pop rivets work best when securing to thin aluminum. Hope this helps.

[Wables]

Not a flame, but I wouldn't use the sabre saw in your situation. You only have 1/16" of scrap around the 4 1/8" hole, which is about the width of the sabre saw blade. Tough cut. A dremel or a 4" right angle grinder would work well. Make sure to patern the hole first! Good Luck!

Wables

[gonfshn]

Try to mount the speakers without cutting. The carpet thickness may offset the 1/16. A soldering iron works well to remove carpet but watch the smoke & fumes, especially around any adhesive, it's rough on the eyes. Try a file if you want to control the result on minimal material removal.

[Stormsearch]

Use the RotoZip, similar to the Dremmel but comes with the cutting bits. I installed a compass with a 3" cutout this spring. I had to go through 1/2" fiberglass, 3/8" wood, and thick carpeting. The fiberglass was on the outside and carpeting inside a storage compartment. One easy cut, you won't believe how easy.