Thread: Cutting holes in the Defender

Originally Posted by crump

How big a hole? I use a step drill for up to 30mm, best thing I ever bought.

I must concur with Crump, it is much neater than a hole saw. Jaycar have got them for only $20. I now carry a smaller drill set and a step (tapered / reamer) bit. It's cheaper than a single good quality larger drill bit and a lot more compact & useful.

predrill with a 2m hole, put a cutout of the size circle you want over than.. make sure its all good from the outside (IE doesnt foul on a light or hinge bolt) then do the same on the inside.

Id then masking tape the area and then measure the depth of the drill bit to the depth you need then check the inside for the depth of protrusion. Get into it with the step drill (paint with white paint pen the step AFTER the one that is the size you want)

IF thats all good get into it spraying the bit with CDT or similar every second step or so.

leaving the tape in place (if it hasnt shredded away) go and get a thin piece of emery tape and break it over a round file then "saw" the emery paper lightly around the hole to remove the shape edges.

Remove the tape and clean up with metho.


the same principal applies for doing it with a hole saw but you dont need to check for depth of protrusion quite as accurately.