Any tips on drilling hole through sheet metal?

Jun 7, 2009
4
I installed a used AG pool and the return hole ended up lining up in the middle of one of the support uprights. I patched the hole with a galvanized plate and now need to drill a new return. Any tips?
Stephan
 
Go to your local hardware store and get a bit that cuts progressively larger holes. Not sure of the name but here is a pic.

You first use a drill bit to start and then you use this to progressively cut larger and larger until you have what you need. Do go really SLOW, one step at a time. You can cut a bigger hole but you can't undo it.[attachment=0:2dqcyah8]IMG_5185_a.jpg[/attachment:2dqcyah8]
 

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Get a hole saw for metal. Use a center punch for the pilot bit and drill slowly. You could also spray some lubricant to help with the cut. Pool walls are thin so It should not take you very long with a good drill. Just make sure you get the right size hole saw.
 
Any of the above suggestions will work.

The main thing you need to do once you are done is to make sure you file and smooth the edges of the cut when you are done.

You want to be able to run your finger around the cut and not feel any burrs or jagged edges.
 
Wolfmarsh said:
Any of the above suggestions will work.

The main thing you need to do once you are done is to make sure you file and smooth the edges of the cut when you are done.

You want to be able to run your finger around the cut and not feel any burrs or jagged edges.

Be careful when running that finger around that hole to check for smoothness, it will be razor sharp!!
 
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