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Old 08-21-2011, 09:09 AM   #1
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Default Cutting Large Windshield Hole w/ Hole Saw

Hi All, I have read a lot of posts on the topic and would like some advice on drilling the large holes in the windshield and back window of my nice new sedan body.

A lot of posts say a hole saw works great for this. I have a set of hole saws for woodworking, is that they type they are talking about? The have a drill bit in the middle that acts as a pilot and then different size hole drill pieces?

The reason I ask is because the teeth on these things are pretty course since they are for wood. Won't they rip the plastic up instead of cutting smoothly? Do you use a fast drill speed or slow? Thanks for any tips, all the other holes I did are perfect and I don't want to mess up this custom painted body.
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Old 08-21-2011, 09:15 AM   #2
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I should also mention that I have another custom painted truggy body that I need to cut the engine hole for and that is a big hole. The hole saw method looks like the easiest way to get it perfect. I looked at the hole cutting tools with the exacto type blade but I am not confident using one of those.
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Old 08-21-2011, 09:19 AM   #3
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I have used hole saws before, it works well but you do need to be careful.

A better option is an Olfa circle cutter.

http://www.olfa.com/CircleCuttersDetail.aspx?C=51&Id=65
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Old 08-21-2011, 09:37 AM   #4
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Quote:
Originally Posted by wingracer View Post
I have used hole saws before, it works well but you do need to be careful.

A better option is an Olfa circle cutter.

http://www.olfa.com/CircleCuttersDetail.aspx?C=51&Id=65
Did you use a slow drill speed? Did you back up the other side with wood? Or just drill slow and don't push hard on the drill?

The reason the circle cutter won't work on the truggy is the hole is almost against the cab so I can't get the cutter in a complete circle because the non=cutting end will hit.
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Old 08-21-2011, 09:47 AM   #5
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just use curved lexan sissors. with the windshield just take a tire trace a circle, use your hole reamer put holes at the edge of circle and cut around the line with the sissors. simple
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Old 08-21-2011, 09:48 AM   #6
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You didn't mention truggy, this is the onroad thread

I just used a cordless drill and went slow.
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Old 08-21-2011, 10:41 AM   #7
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The standard hole saw that is used for wood yields a nice clean cut. The inner and outer edges are sharp, just use sandpaper to remove the edge. I use my electric drill.
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Old 08-21-2011, 11:05 AM   #8
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I use a Greenlee chassis punch. Makes round, square, or oval holes from 1/2 to 1 1/2 in diameter. Just drill a hole in the center of where you want the hole to be, insert the bolt with cutting head, then screw on the bottom cutter & tighten. Does a great job of making clean cuts & doesn't warp or burn the Lexan!!!
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Old 08-21-2011, 11:17 AM   #9
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Quote:
Originally Posted by Jake C6R View Post
Did you use a slow drill speed? Did you back up the other side with wood? Or just drill slow and don't push hard on the drill?

The reason the circle cutter won't work on the truggy is the hole is almost against the cab so I can't get the cutter in a complete circle because the non=cutting end will hit.
With the circle cutter can you cut half the hole from the outside and the other half from the inside?
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Old 08-21-2011, 11:18 AM   #10
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Thanks guys for all the advise and tips. Looks like a lot of different ways to accomplish the same thing, some of them I never knew!

I would normally just jump in and try it but I have never spent this much on two bodies so I am cautious about screwing them up. But I have plenty of info now to get it done.

Thanks again!
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Old 08-21-2011, 12:27 PM   #11
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Default Here Is The Finished Product...

OK well I tried the hole saw and I didn't like it. Unfortunately it grabbed and spun the body a little, putting some scratches on top from the wood I was backing it up with.

Fortunately I used a smaller hole saw than was ultimately needed and it had gone part way through.

So instead I used a shot glass and traced a circle on the front and back, then used a very sharp exacto to score it. After that I cut pie shaped pieces into the score from the middle and snapped the pieces off.

Then the dremel drum sander and cutting blade for the flat parts to clean it up. It's not perfect but not too bad - next time I will be better.

I will post a couple pix so you can critique my work, thanks again for the support guys.
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Old 08-21-2011, 12:54 PM   #12
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Default Pix...

Here is the sedan body...




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Old 08-21-2011, 12:57 PM   #13
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Default Next...

Next is the truggy body to work on these body cutting skills...(I know, wrong forum LOL)



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Old 08-21-2011, 01:28 PM   #14
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Quote:
Originally Posted by wingracer View Post
I have used hole saws before, it works well but you do need to be careful.

A better option is an Olfa circle cutter.

http://www.olfa.com/CircleCuttersDetail.aspx?C=51&Id=65
+1...the circle cutter and a pair of curved lexan scissors should be all you need.
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Old 08-21-2011, 03:30 PM   #15
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If you're going to use the pilot-bit style hole saws, that are
made for cutting wood and sheet metal, on a lexan body. Get a reversible
drill and use the saw in reverse rotation to drill the lexan. It will cut
the lexan alot smoother without digging the teeth of the saw
into the body and possibly ripping the body up.
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