Cost. The hole needs to be a minimum of 6 inches in diameter.
I have an adjustable cutter but it's not designed for steel.
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Starrett list a 6" holesaw. Catalogue price US$59.49 bare saw, US$79.86 saw with arbor and pilot drill. Don't know what Oz distributors charge but as most are greedy, probably at least three times those figures in A$. I estimate I could supply the second direct from the US by air mail for around A$180 @ exch. rate of 0.80
Would a reciprocating saw do the job?
Well if you have a Plasma!!!
One arc in the middle of the circle required outa do it... the edges of the hole may be a little ragged and the tank a little second hand but would be quick!
What sort of clearance between floor pan and tank top.
Would be a sub-optimal outcome if you made a beautiful spark free incision through a breather line or the tank itself? Cant be that hard to drop / lower the tank - or can it!
Steve
the blade will make some sparks not much but it only takes 1, also the swarf that they produce is very hot, ive worked as a boat builder for years and thats all we used to cut the aluminium, you have to be very careful with thin material as it can grab. believe me when i tell you that when those blades bite the will not let go, i would suggest getting the biggest hole saw you can and bite the bullet and use a rattail file unless you are confident in the use of those blades. hope this was some help