Maybe someone will come up with a better way to deal with shavings.

But for a rectangular hole, I'd use a cutting wheel in a die-grinder. You can even drill smaller holes at the corners, and file a larger radius.

For round holes, I'd go to Home Depot and get a Malco sheetmetal router that fits in a drill. They are less than $50, and have a range of adjustments for hole sizes. It uses a special drill bit on an adjustable arm to drill the hole, such as 6" diameter. This will create a perfectly round hole. I used one of these on numerous parts of my aircraft.

L.Adamson --- RV6A
 
avee8tor13 said:
What is the best way to cut an access panel in a fuel tank?
My concern is metal shavings.
Click to expand...

One way is to mount the tank in a cradle, then cut an access panel in the rear baffle using a fly cutter in your drill press.

What part of the tank do you need to access, and is the tank on the airplane?
 
Basic Shop Practices

avee8tor13 said:
What is the best way to cut an access panel in a fuel tank?
My concern is metal shavings.
Click to expand...
Your gonna get shavings. That's not a problem. If the tank had fuel in it, I'd be far more concerned with explosive fumes ruining your day. To replace a rusted filler flange, I had to cut in an access hole in a Piper Cherokee fuel tank which is similar in construction to RV fuel tanks. The first thing I did was flush the tank out with water. I then refilled the tank with water again (to displace any remaining fumes) before cutting the opening into it. Using a fiber cut off disc to rough cut the opening, I then followed up with a common 1" rotary file fitted to the same die grinder to remove the remaining material up to the (previously etched) scribe line.

8wm8fm.jpg
 
thank you gentlemen

I am working on a fuel tank that has not been installed or has had fuel in it. I am going to cut a hole in the back on the tank (RV-10) with the tank on two saw horses thus the shavings would fall away from the tank.
 
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