Looking for some advice from some of you fabricating experience folks. I need to make a 2.5 inch hole in a 3/16" steel bumper. Can I do this with a bi-metal holesaw from my local Home IMprovement store? I have a heavy duty drill...

 

As long as it is a good quality bi metal blade like a Lennox or similar, and make sure you lube it often so it won't overheat. Heat kills the blade real quick.

 

I cut 4 inch holes in my PJ rear bumper with a standard hole blade and cordless drill......no issues. I would also recommend WD-40 or some other lube to keep it from overheating and eating the teeth.

 

Great info - Thanks to you both!

 

And drill slow, a lot slower than you think.

 

Thanks guys... I have been planning to relocate my trailer plug and need to do the same.

 

WD40 is good, light oil better, but watch out for the hot chips! They can really hurt and with the oil stick right too you.

X2 on going as slow as possible (reasonably) it with the oil will extend the hole saw life.

 

X2- The slower the better, as soon as you heat up the hole saw the teeth will dull quickly.
No lube is really needed for material that thin, but if you must use Pledge.

Pledge will work better than WD40. It is water based and unlike a
petroleum based lube it will not try to lubricate the teeth while cutting.
It will merely keep the teeth cool enough not to get dull.

 

Thanks to all - worked great :