CHASSIS, Drill your axle!

[Flat Ernie]

Originally Posted by ELpolacko

I reccomend some good hole cutting music, something Texas based like ZZ Top, Junior Brown, ButtholeSurfers. Drilling holes is in these guys blood!

Yeah - that worries me a bit - drilling holes with the butthole surfers...

Great tech!

[rodwerkz]

Awesome post.. I originally was going to drill my axle too but I was getting lazy... Your finished product looks so cool I'm going to have to do it.

Just a note on hole sawing thick and or hard material: If you drill one or two 1/8" holes right inside the diameter of the hole saw it will cut a whole lot easier. These holes allow chips to escape, lube to get in, and give the hole saw a better bite. It will cut your time in half and save you wear on your blade. See below:

[C9]

Blue Mol saws

Haven't seen that brand, but I'm guessing they are bi-metal are they not?

I use hole saws fairly often.
Mostly in alumimun, now and then in 1/8-3/16" steel.
(T McG's post done today (Hole Saw Trick) is a good one for larger holes.)

As a fwiw, I like to drill pilot holes prior to cutting with hole saws.
Makes the hole saw cutting bit easier since you're only doing sawing if you have a 1/4" pilot hole.
Easier to gauge the pressure as well.

Good post, you've got me thinking a drilled axle would look great on my 31 roadster.

[TomH]

Originally Posted by lowsquire

When i drilled mine i reduced the hole sizes at the ends ,i thought it would look kool, just realised this photo doesnt really show the holes! oh well. use your imagination

My imagination isn't worth a shit, would like to see your axle.

[atch]

El P,

do you chamfer the holes?

how's the best way to do so?

do they make chamfer bits that large?

[ELpolacko]

This guy wanted the crisp edge so I just deburred it with a half round needle file and left as much as I could.

I have seen chamfer bits large enough but fitting down in the web might be an issue so the best bet is a file and some patience. I have gotten pretty good with my Dynabrade mini belt sander but would worry about it getting away from me.

Good work takes time.

Originally Posted by atch

El P,

do you chamfer the holes?

how's the best way to do so?

do they make chamfer bits that large?

[KIRK!]

Nice post. I've always used a hole saw. Well, the first two holes in the first axle was with a regular $60 bit which bacame a paper weight.

I always tell people there are five steps:

1) measure
2) measure
3) measure
4) mark 'em
5) drill 'em (and that you can never use too much cutting fluid)

[SamIyam]

BTTT, as a tech week runner up and all around cool post...

Sam.

[Greezy]

Originally Posted by atch

El P,

do you chamfer the holes?

how's the best way to do so?

do they make chamfer bits that large?

He atch I used a flapper wheel after I drilled this one gave the holes a slight chamfer. I drilled this one using 7/8" hole saw.

[Roothawg]

Good stuff.

[ELpolacko]

I was notified that the photos got lost in one of the HAMB upgrades. I just posted them over on my PhotoBucket account.

Here is a link to the photos for this thread.