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Thread: Tip: Drilling an existing hole to larger size

  1. #1
    Branching Member mothra's Avatar
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    Tip: Drilling an existing hole to larger size

    In all my frustration with the pump install I almost forgot about this. I needed to use a 1" bulkhead where I currently had a 3/4" bulkhead drilled in my sump. You obviously can't just put the hole saw against the sump and go to town or it will walk all over the place, which is why they have the 1/4" drill bit in the center of the hole saw.

    I used a trick I learned as a machinist, may or may not be new to some of you. Take a small piece of 3/4" or thicker wood and drill it with your larger hole saw. Now take this board and line the hole up with the existing smaller hole on your tank/sump and tape it against the sump w/ masking tape all the way around. Now you have a guide to drill the new hole with.

    If you want real precision measure from the 2 closest edges of your sump to the existing hole, now select a board big enough to line up with those edges and transfer the hole location dimensions to it then drill. Now you just have to line up the edges of the board w/ the edges of the sump and tape it in place, both holes should be on center.

    Maybe it will help someone out one day. This is also a good technique for drilling holes on the edge of things where your bit wants to walk off.


    Jacob.
    Jacob

    Tank(s): 360g Reef

  2. #2
    CVR Webmaster / Director Emeritus whodah's Avatar
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    nice trick!
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  3. #3
    Branching Member BammBamm's Avatar
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    Good Idea. I've done that myself before and it works great. Also if your really hard up you can use a Dremel to enlarge the hole..
    People that tell you money is the root of all evil don't have any.....

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  4. #4
    weatherson
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    Another way to do this is to use a hole saw slightly larger than the existing hole but smaller than the hole to be drilled. Drill out a hole in some scrap acrylic and save the "plug" that is removed. Align and glue with #4 solvent this to the backside of the hole. Then drill the hole using the center bit hole as a guide. The larger hole saw will remove this temporary plug. Very similar technique to yours but does require a good selection of different hole saw sizes be available.

  5. #5
    Branching Member mothra's Avatar
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    I thought about something like that but didn't want to pony up about $5 for a cheapy hole saw
    Jacob

    Tank(s): 360g Reef

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