Just got a replacement front door, the usual Stanley steel type. I want to
put one of the oversized peepholes in it that rquires a 1 inch hole. What
is the best way to make such a hole? I'm assuming the good old spade bit
won't work, and my little cup saw/drills won't like the metal either. Any
If you are just punching one door a regular black bell to fit your mandrel will
work. Just plan on throwing it away. I punched two 2" <guage> holes in an old
metal dash board with one and that is a lot thicker metal than a door.
It was smokin a might there toward the end tho. The paint on the dash was OK
to the industrial supply and get a proper hole saw for metal (or even just a
1-inch bit, if they carry them that big), but for a one-time job, that is
probably pretty expensive. I'd carefully lay out and scribe the hole, from
both sides, and drill lotsa tiny holes inside the scribe line. Drill a pilot
hole all the way through, to keep your centers lined up. Eventually, you
will get it to the point you can pop it out of there, and clean up the hole
with a file. The skin metal on a residential-grade door is thinner than a
car fender, in most cases. Use sharp bits, and try not to lean on the door
as you work- center section of most cheap steel doors is just filled with
foam, and it is easy to make things look like a crushed and straightened
beer can. Recommend one of those collar things on the drill, or even a
pre-drilled block of wood to use as a jig, to keep bit perpendicular to the
plane of the door.
Sorry to jump in so late, but one thing you could use is a unibit:
They're expensive for a one-time use, but if you think you will ever
use it again, it's a great thing for enlarging existing holes in metal.
Any decent hardware store would have these.
A good quality holesaw will drill through a steel door. Morse and
Starret are 2 brands that come to mind, I once used a Craftsman and it
was about shot when I finished, but OTHO, they replaced it under their
On 1/24/2005 2:32 PM US(ET), Lawrence Wasserman took fingers to keys,
and typed the following:
I used a 3/4" holesaw to drill a hole in the top of a stainless steel
sink for a separate drinking water fountain (bypassing the water
softener). By the time I got 1/2 of the way through, it was just burning
a groove in the SS. I didn't have another 3/4" holesaw, so I continued
until I had burned through enough SS to be able to punch the disk out. I
had to finish up the hole with a quarter round metal file to smooth some
rather nasty jagged edges. I wonder if it was a Craftsman and I could
have gotten a replacement? I wound up buying a new 3/4 holesaw at HD on
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