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 Tiny Camper 
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Location: Faxon, OK
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Real Name: Chuck
I'm "converting" a 5X8 utility trailer into a mini camper. For my electrical/solar system I plan to run the wires between the battery box (outside) to the inside of the camper. I bought one of those outlets you see on a regular camper that your 30/50 amp cord comes out for my electrical system as the pass through. The hole required is a 2.xx inch. Not 2.5, or 3 inch but a weird diameter. I need to cut the hole through the VERY thin aluminum skin of the trailer. Instead of buying a hole saw for one use, can someone suggest a way to create a hole for the wiring of the battery to the interior? Silicone glue will seal any gaps reducing the need for an exact size. Don't want to buy a hole saw to drill a hole that I will never have to use again.
Tools available:
Rechargeable drill with bits to 1/4"
5.5" Circular saw
Scroll saw

Ideas?

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Wed Oct 31, 2018 6:49 pm
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Tin snips? Or draw the circle and then drill 1/4" Holes around the circumfrence connect the dots style, then worry the bit between the holes to break out the disk. 12 gauge from 2 feet away?

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Wed Oct 31, 2018 7:14 pm
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Just get the right tool for the job & make it look clean & professional.
If you need one I can send it to you to use & send it back. :wink05:

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Wed Oct 31, 2018 7:46 pm
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sheet metal hole cutter

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Wed Oct 31, 2018 7:48 pm
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Traut wrote:
Tin snips? Or draw the circle and then drill 1/4" Holes around the circumfrence connect the dots style, then worry the bit between the holes to break out the disk. 12 gauge from 2 feet away?

:ROFLMAO: :ROFLMAO:
LOL!!!!Fire in the hole!!!! icon_eek :ROFLMAO: :ROFLMAO: :ROFLMAO: :popcorn:

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"You are either with us...as Americans. Or, You are against us. There is no IN BETWEEN." ???

"We cannot negotiate with those who say, 'What's mine is mine, and what's yours is negotiable.'" JFK

"Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety”

-Ben Franklin

MadPick wrote:
I don't think you beat your children enough. :ROFLMAO:


Wed Oct 31, 2018 7:49 pm
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jukk0u wrote:
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sheet metal hole cutter


Those work great too. :wink05:

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"You are either with us...as Americans. Or, You are against us. There is no IN BETWEEN." ???

"We cannot negotiate with those who say, 'What's mine is mine, and what's yours is negotiable.'" JFK

"Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety”

-Ben Franklin

MadPick wrote:
I don't think you beat your children enough. :ROFLMAO:


Wed Oct 31, 2018 7:49 pm
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Can’t say I’ve seen a step drill that goes as big as he needs. It would be stupid expensive if there is one.

A dremel/rotary tool with a small cutoff wheel would work


Sent from my iPhone using Tapatalk

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Wed Oct 31, 2018 8:38 pm
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just go to home depot and get a hole saw. I went there and the guy is like, use it and bring it back happens all the time. its what I did.

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Wed Oct 31, 2018 8:46 pm
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Do you have room for a jigsaw with metal cutting blade. Tape over the surface to prevent marring. Cut inside the line and file with a half round for final cleanup.

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Wed Oct 31, 2018 8:49 pm
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Scissors.

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Wed Oct 31, 2018 10:44 pm
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Use a Pin Router bit. Google it if needed. $5 or less. It’s like a drill bit, but also cuts sideways in alluminum Common in aircraft sheet metal work


Thu Nov 01, 2018 1:36 am
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Maybe a nibbler would work: https://smile.amazon.com/dp/B00MPHC4TQ? ... f=aa_scomp

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Thu Nov 01, 2018 7:15 am
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Personally, I say buy the hole saw. Chances are good that you'll end up needing it again. I always use a project as an excuse to buy more tools and usually I'm glad down the road that I did. But I'm also a hoarder, so maybe you don't want my advice.


Thu Nov 01, 2018 8:47 am
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He's cutting through thin aluminum. A hole saw will probably just rip it up

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Thu Nov 01, 2018 9:02 am
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RocketScott wrote:
He's cutting through thin aluminum. A hole saw will probably just rip it up


Well, he mentioned the hole saw--not me! I'd probably buy one anyway, just to be safe... And then end up not using it!


Thu Nov 01, 2018 9:18 am
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