Hole making in alloy

[crankedup]

Soon I shall need to make two holes in the scuttle of my vintage car in order to fit vents. Each hole will be approx' 40mm and as the scuttle is in place (car in use)I will have to 'do' the holes whilst scuttle is in place. The alloy scuttle is single sheet and I guess 2/3 mm thick.
Are there any special tools available to do this job as I obviously don't want to deform or stretch the alloy surrounding the work areas. Thanks.

[Trooper2]

Hole saw and a drill motor.

Hole Saw:

http://en.wikipedia.org/wiki/Hole_saw

Put down some masking tape to draw where you want the holes and to protect the surrounding area.

Edited by Trooper2 on Tuesday 18th September 19:38

[The Griffalo]

If you can clamp/wedge a piece of wood to the reverse side it will help

[lotisi]

Get one of these http://www.averytools.com/pc-234-97-panel-master-i... they are available in this country for sensible prices or you may be able to borrow one from a racing car manufacturer.

[crankedup]

Thanks guys for links and advise. Averytools site is down at the moment, any others?

[GreenV8S]

If the metal you're cutting is flat then I reckon your best bet is a hole punch. In case you haven't seen these, think of two close fitting cylinders with a screw thread to pull them together. You simply drill the center out, put the punch in place and wind it closed. You'll have no trouble cutting 40mm in material that thin.

[crankedup]

GreenV8S said:

If the metal you're cutting is flat then I reckon your best bet is a hole punch. In case you haven't seen these, think of two close fitting cylinders with a screw thread to pull them together. You simply drill the center out, put the punch in place and wind it closed. You'll have no trouble cutting 40mm in material that thin.

New to me an 'hole punch'. The scuttle is'nt flat tho' well not quite, its my Austin 7 Swallow saloon which I am fitting the vents too. You most likely are familier with that car anyhow. Its the 'ships funnel' style vents I'm fitting.