I need to cut a couple of larger holds, beyond the range of my drill bits - one 1-1/8" diameter and another 1-5/8, both in copper. The 1-1/8 hole is in a curved surface and both holes need to be accurate enough to fit tubes with a silver soldered joint. Being inherently frugal, I am trying to determine the most economical method.
Hole saws are the most economical but are notorious for producing inaccurate holes.
I could buy a drill bit for each size but they run between $50 and $90 each and I only have a total of 3 holes to do.
Hollow mills (plug cutter?) are also fairly pricey.
I could bore the two larger holes in the lathe but that doesn't solve the problem for the smaller hole in a curved surface.
I have a smallish fly cutter that I might be able to set accurately enough to cut the holes on the mill but that's a bit risky.
I don't have any steel stock of a large enough diameter to make a circular cutter.
Are there any economical options I am over-looking? How would YOU go about it?
Thanks!
Hole saws are the most economical but are notorious for producing inaccurate holes.
I could buy a drill bit for each size but they run between $50 and $90 each and I only have a total of 3 holes to do.
Hollow mills (plug cutter?) are also fairly pricey.
I could bore the two larger holes in the lathe but that doesn't solve the problem for the smaller hole in a curved surface.
I have a smallish fly cutter that I might be able to set accurately enough to cut the holes on the mill but that's a bit risky.
I don't have any steel stock of a large enough diameter to make a circular cutter.
Are there any economical options I am over-looking? How would YOU go about it?
Thanks!
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