Battery box lightening holes

dougweil · #1 01-26-2010, 04:14 PM

Hi guys:

Just got Van's battery box (steel) and wondered what you have been using to cut the lightening holes. I did cut one 2" inch hole on the with a hole saw backed up with a block of wood, but it was a BIG effort and ruined the hole saw. Plus it left a big lip on the back which I had to file and polish down. I thought about a fly-cutter but not sure just how that might work. I have 7 more to go if I want to cut them all.

Any good ideas???

JonJay · #2 01-26-2010, 04:33 PM

....lots of lube and go slow. Cheap hole saws at high rpms dont last long.
If you have access to a set of Greenlee punches, they work very well and leave little burr to deal with.

A fly cutter has the same issues with heat and speed. You can ruin a fly cutter tip in a heart beat but they are easy to grind back into shape and heat treat again if you know what you are doing. Once you ruin the temper with heat, you are done.

Rick6a · #3 01-26-2010, 04:42 PM

As I have routinely done generating uncounted lightening holes prior to today's advanced kits, with cutting oil bathing the work, I used a fly cutter chucked into a floor mounted drill press, turning at 250 RPM. Some may say even that speed is too fast but I've never experienced the slightest trouble. Because a fly cutter can be dangerous, always make certain the work is clamped down securely and don't force it. In this particular case, I also stuffed a chunk of wood into the steel box so it could not distort as I cut into it. Worked well for me. YMMV.

AX-O · #4 01-26-2010, 04:50 PM

Would an instrument hole punch like this one work

http://www.skygeek.com/ats-123c.html

Mel · #5 01-26-2010, 05:14 PM

Quote:

Originally Posted by Rick6a

As I have routinely done generating uncounted lightening holes prior to today's advanced kits, with cutting oil bathing the work, I used a fly cutter chucked into a floor mounted drill press, turning at 250 RPM.

I use 170 rpm.

apkp777 · #6 01-26-2010, 05:23 PM

I didn't put the holes in mine as I thought the weight to frustration ratio was not worth it. I am curious to find a good solution though. It's not too late to drill em.

Bavafa · #7 01-26-2010, 05:30 PM

Hole punch kit from Harbor fright does a good job and it is easy on the budget.

jsharkey · #8 01-26-2010, 05:38 PM

Quote:

Originally Posted by apkp777

I didn't put the holes in mine as I thought the weight to frustration ratio was not worth it. I am curious to find a good solution though. It's not too late to drill em.

But why oh why did the factory design the installation with the attachment bolts on the inside of the firewall and inevitably underneath the bonded insulation blanket? And why oh why didn't I change it?

Jim Sharkey
RV-6 Phase 1

MJarreau · #9 01-26-2010, 07:11 PM

Looks sort of like what we use with our Greenlee punch at work. It requires a hydraulic (manual) pump. But, ours works like a charm.

gasman · #10 01-26-2010, 10:24 PM

Quote:

Originally Posted by apkp777

I didn't put the holes in mine as I thought the weight to frustration ratio was not worth it. I am curious to find a good solution though. It's not too late to drill em.

This is the best answer posted on this subject so far......

I did not cut out the holes..... Just placed the battery sticker on it.