[TowerTalk] Cutting Large Holes in Aluminum

[Mike Wetzel]

I have aluminum rectangular blocks (4"x4"x1") that I need to cut a 3"
diameter hole in (using them instead of muffler clamps).  I tried a bi-metal
hole saw and also a circle cutter with not much success since I need to make
about blocks altogether.  I have a metal lathe that I can bore the finish
diameter on but I would like to get a big chunk of the material out of the
way (to save some time).  I have also thought of using a smaller drill bit
(1/2") and drilling a series of holes around the diameter and may do this
but there seems like there has to be a better (less labor intensive) way.

Thanks

Mike W9RE


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