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Posted: 4/25/2024 5:30:40 PM EDT
[#1]
You could drill the corners first, then 3" whole saw, then just take out what's left with the die grinder.
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Posted: 4/25/2024 5:35:40 PM EDT
[#2]
Quote HistoryQuoted: You could drill the corners first, then 3" whole saw, then just take out what's left with the die grinder. I would probably use a hole saw that provides the proper radius in all 4 corners and then make the straight cuts with a cutoff wheel in a grinder. |
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Posted: 4/25/2024 6:11:20 PM EDT
[#3]
Drill the four corners with 1/4" - 3/8" drill, and cut from hole to hole. A few holes in a line lets you make a starting place for a saw. Sawzall, saber saw, hack saw, 3" air compressor cut-off tool, or whatever else works for you.
Use plenty of tape to protect the finish around the cuts. |
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Posted: 4/25/2024 6:47:47 PM EDT
[#4]
That big of a hole saw will not make a nice 3" hole.
As stated, drill each corner and then cut out the middle with a saw. A Jig Saw with metal cutting blade will be easiest to control and produce less heat. |
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Posted: 4/26/2024 7:15:48 AM EDT
[#5]
Since it's such a small hole, you might have to use a jigsaw with a quality metal cutting blade.
Cover the area with masking tape and do the layout on the tape. Don't forget to paint the cut areas or you'll have corrosion working its way under your nice powder coating. Post a few pics when you get it done, I'm sure we all would like to see the finished product. |
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Posted: 4/26/2024 7:27:32 AM EDT
[#6]
Quote HistoryQuoted: That big of a hole saw will not make a nice 3" hole. As stated, drill each corner and then cut out the middle with a saw. A Jig Saw with metal cutting blade will be easiest to control and produce less heat. This |
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Posted: 4/26/2024 7:30:53 AM EDT
[#7]
One 3" square hole in 12 ga would not be a bad job for a drill and then hacksaw.
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Posted: 4/26/2024 7:38:42 AM EDT
[#8]
Quote HistoryQuoted: Drill the four corners with 1/4" - 3/8" drill, and cut from hole to hole. A few holes in a line lets you make a starting place for a saw. Sawzall, saber saw, hack saw, 3" air compressor cut-off tool, or whatever else works for you. Use plenty of tape to protect the finish around the cuts. Cut the straights a bit undersize and file to the line |
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Posted: 4/26/2024 7:53:57 AM EDT
[#9]
Based on the thread title, i was gonna say use a mill.
That would be way more precise than any of the suggestions. But i think it may be overkill for the actual question. Taking off the bumper and mounting it in the mill is a lot of work for some level of precision that isn't really required. You're looking at using a couple different power tools, by hand. The cuts aren't gonna line up perfectly or be placed exactly where they need to be. Come back and clean it all up with a hand file. |
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Posted: 4/26/2024 11:59:53 AM EDT
[#10]
Use a plasma arc cutter, then clean it up with a grinding wheel.
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Posted: 4/26/2024 6:56:48 PM EDT
[#11]
Drill the corners, saw the sides.
FWIW, a hole saw will cut an acceptable hole if you first use the holesaw to put a hole in a 3/4" thick piece of hardwood and then clamp the wood to your part to use as a guide for the saw. It tames down the wobblies quite a bit. |
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Posted: 4/27/2024 9:54:06 PM EDT
[#12]
air saw would probably be good here.
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Posted: 5/1/2024 5:13:28 AM EDT
[#13]
Drill the corners and mark a bright line between the holes. Then use a skinny wheel on the side grinder to plunge in, the larger diameter wheel the better. The goal is to cut the whole length without moving the grinder, this prevents you from wandering in the cut.
You'll get a straight line very quickly. May have to touch up the corners. That said- a plasma torch, a soapstone and a speed square will take you a long ways down this road. |
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Posted: 5/2/2024 1:47:08 PM EDT
[#14]
Quoted: Drill the corners and mark a bright line between the holes. Then use a skinny wheel on the side grinder to plunge in, the larger diameter wheel the better. The goal is to cut the whole length without moving the grinder, this prevents you from wandering in the cut. You'll get a straight line very quickly. May have to touch up the corners. That said- a plasma torch, a soapstone and a speed square will take you a long ways down this road. This all day. Also do a test run on some other material. Doesn’t even have to be metal. |
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