Best way to make holes in dash

[bil1024]

I've tried drilling in the past, gets boogered up, any suggestions ? thanks

[jimgood]

When you say you've tried drilling are you talking about hole saws?

[Jeff Kleiner]

Hole saw and/or circle cutter for the gauge holes and a step bit for the switches, indicators, etc.

Jeff

[bil1024]

I have tried bits and hole saws, making holes for switches and indicator lights

[wallace18]

I use hole saw and step drills but use a drill press with a block of wood under the aluminum. This keeps the bit from walking IMO.

[6t8dart]

Hole saw or punch, and step bits for smaller holes. I have used a body saw in the past, but it took a long time. Punches are best for clean holes, but can be hard to find in some sizes, holesaws work good if you use a block of wood under and make sure all the screws are tight and there is little wobble in the bit while spinning. A sharp saw will make a hole in seconds in aluminum.

[chopthebass]

I agree with Dart. I used Milwaukee hole saws with a block of wood underneath and works great. Slow speed and lube needed. I think I even screwed the aluminum to the wood.

[6t8dart]

Also, don't forget to tape the face of the panel, shavings can whip around and scratch it up.

[myjones]

If all your layout is done full size on the front of the dash you can clamp a piece of plywood on the front, just drill it first with the holesaw then when you clamp it in place you can see exactly where the hole will end up. You can even remove the pilot bit once the wood is drilled and just let the plywood keep the saw located. Plywood is best for that template because it won't split off while drilling and let the saw run amok.
DB

[skullandbones]

I like the plywood template idea. However, I have always done it with a punch and step bit on a drill press.

WEK.

[pcww]

I used this: General Tools & Instruments 55 Heavy Duty Circle Cutter from Amazon.
Worked perfectly. A little time consuming to get the size exactly correct but once you have it all of the similarly sized holes can be drilled at the same time.

[2FAST4U]

Hole saw and/or circle cutter for the gauge holes and a step bit for the switches, indicators, etc.

Jeff

Ditto that

[edwardb]

Cut this dash a few weeks ago with an old Craftsman circle cutter and various step bits. The circle cutter looks exactly the same as the current General Tools one already mentioned. They work very well and you can get the dimensions exactly right. Just make sure the tool piece is sharp (they resharpen easily), go slow and don't overheat it, and a little cutting oil helps. Not mentioned, but this is only a drill press option. I cut part way through, then flip over and finish from the other side. Both sides come out nice and clean that way. BTW, the glovebox opening was with a sabre saw and then cleaned up with a sanding drum in the drill press.

http://i867.photobucket.com/albums/ab234/edwardb123/Factory%20Five%2020th%20Anniversary%20Mark%204%20R oadster/Instrument%20Panel/th_IMG_3666_zpstozoedbc.jpg (http://s867.photobucket.com/user/edwardb123/media/Factory%20Five%2020th%20Anniversary%20Mark%204%20R oadster/Instrument%20Panel/IMG_3666_zpstozoedbc.jpg.html)

[CraigS]

I know this is a little different application than the OPs question but add it in case anyone is in a similar situation. I needed to add a switch to by 9 year old foam backed vinyl covered dash. Decided to finally step up to one of the $40 step bits. I was amazed. I drilled right into the dash, going slowly, went through the covering and the aluminum. And the cover was pierced but left in plenty good condition to be pushed through the hole and captured by the switch nut.

[cgundermann]

For the smaller holes - the affordable titanium step bits from Harbor Freight work well with plywood underneath the dash (plenty of WD40 and tape off the aluminum).