drilling 4 1/2 inch hole in metal panel

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Hole saw, and a good drill. Jig saw would work as well, if you're good at following a line.


SceneryDriver
 
Punch- ?
Every electrician should have a set, Borrow the ones you don't have.

Holesaw that big in metal. Make sure your insurance is paid up.
 
Reminds me of a time I was working for an electrician that had to drill into a panel. He gets the appropriate size hole saw, and starts drilling away. I politely pointed out to him that unless he wanted to drop the metal slug and or chips across the LIVE 480 volt 3-phase mains with the dead front off, and create a giant fireball , that it might be a good idea to secure power first.

Tl;dr... Secure power first. And a bimetallic hole saw will work fine.
 
If you have a drill that can go slow (<150 RPM) oil and a 2 cutter trepanning bit (aka fly cutter) works well. Higher speed is a sure way to increase workman comp premiums. :sick:

An old fashioned brace with fly cutter works well also but may take 2 or 3 minutes per hole, more if you don't have room to swing the handle 360. .
 
drcampbell said:
Use cutting oil.
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Coppersmith said:
I hope for your sake it's not a stainless steel panel.
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The problem with cutting stainless steel is that most people don't know what they are doing. They think that faster speed and more pressure is the right way and they burn up the hole saw. Slower speed, less pressure and cutting oil. You can cut stainless but you have to slow down and do it right. Don't let the saw get hot.
 
If you go the hole saw route, here's a trick I like to use sometimes. Drill the 1/4" pilot first with a standard drill bit. Put a 1/4" smooth rod in the hole saw to use as your arbor.

BUT, I'm in the camp with my first trick to be the jigsaw-sized blade in my reciprocating saw.
 
I am in the buy a punch camp. If not borrow one. Rent one. Take another EC to lunch for one. Check your local apprenticeship program.
 
I agree. My preference for the reciprocating saw (jig saw has a better shoe if you have the room to swing it) would be if the punch had already been eliminated as an option. They are worth it.
 
You can by the Chinese big punch set off eBay for under 200.00. It’s not greenlee, but for the occasional use it works just fine. Then you have a set from 2 1/2” to 4”.


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