Best way to cut a 3" hole in the airstream skin?

[rmkrum]

When I had to trim my water heater hole a bit taller, I grabbed my aviation tin snips after marking the line. Used the left and then the right hand ones to trim away the skin in the way, filed off the sharp edges, and drove on. No hesitation once I triple checked measurements. It's an AS, not solid gold....


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[airator]

Originally Posted by gomotomoto

What's the best way to cut a 3" hole

Yes, one of the most important tools in my toolbox, is a hole saw kit with different mandrels . The best to cut clean holes.

[TinkersToy]

Originally Posted by BambiTex

I have cut four round holes in my vintage AS skin (shore power, water fill, and two for the furnace). I used hole saws for all four. Once the agonizing measurement process was complete, cutting the holes was relatively easy.

If using a hole saw select a metal cut saw and drill slowly counter clockwise to prevent the the teeth from digging in the aluminum.

[NavyCorpsman]

The basic RotoZip tool has a circular guide. Set the tool at a 1.5 inch radius, drill the pilot hole on center, then set the tool to cut the hole. Metal cutting bits are available.
.

[Alumineer]

Originally Posted by GeeSag

Here is just a suggestion:
Try getting a Greenlee hole punch in a much smaller diameter and a hole saw of the same diameter and try both on a scrap piece of aluminum.

One of the best hole saws I've ever bought was this Greenlee carbide cutter. I've used it on aluminum up to 5/16" thick, usually in a milling machine but also freehand, and it does an awesome job. The carbide teeth make for a very smooth cut and a bit of tilt once the cut is started lets you steer clear of the ripping that can occur when you use a dull cutter, or too much speed.

Budget permitting (the 1 1/8" cutter was around $100 if I recall correctly) I would get this 3" cutter and the matching quick-change arbor.

[gomotomoto]

I definitely over-thought it. Skin is thicker than I expected... Made it easier to deal with.

I simply used high speed, and some "feel" ...making sure not to dig down too hard and poking the teeth through systematically. Ended up with two perfect little circle shaped tin can lids!

[J. Morgan]

I have possibly observed a tendency of some folks to over think things on this forum....


Gradiens super tenui glacie.

[HiJoeSilver]

Originally Posted by gomotomoto

I definitely over-thought it. Skin is thicker than I expected... Made it easier to deal with.

I simply used high speed, and some "feel" ...making sure not to dig down too hard and poking the teeth through systematically. Ended up with two perfect little circle shaped tin can lids!

Hole saw?

I think the hardest part is making sure you have the right spot and the thought that you're putting a big hole in your trailer.

[mshumer995]

Of course we're overthinking it, we're cutting holes in our Airstreams.