Got to drill big hole... What might I hit?

[sledhead]

I have used this style drill bit to drill through the floor and not hit the radiant heat line that was right there

worked for me

https://www.amazon.com/MLCS-9245H-3-Inch-Diameter-Forstner/dp/B00EPBVKZO/ref=pd_lpo_vtph_469_bs_t_1?_encoding=UTF8&psc=1&refRID=G9X2YN8YMEVFCWPARG7K

dave

[Oonrahnjay]

not if they aren't stuffed in the bowels of the bus and have adequate space and seperaytion...an inch or two is fine.

a trade off i am willing to make. 

       Yeah, I like AGMs, too.  And people talk about the failures -- don't lead-acid flooded batts fail?

[richard5933]

I have used this style drill bit to drill through the floor and not hit the radiant heat line that was right there

worked for me

https://www.amazon.com/MLCS-9245H-3-Inch-Diameter-Forstner/dp/B00EPBVKZO/ref=pd_lpo_vtph_469_bs_t_1?_encoding=UTF8&psc=1&refRID=G9X2YN8YMEVFCWPARG7K

dave

That would work to get through the plywood upper layer, but in my experience they don't do so well going through aluminum. And I have two layers of that to get through.

[buswarrior]

lubricate that hole saw as you drill, or buy a bunch of 'em!

happy coaching!
buswarrior

[chessie4905]

He's cutting wood and aluminum, no lubricant needed. After you cut through the plywood, youll need to remove plugs before continuing.

[Lee Bradley]

Buy a can of this, or similar, and use it. Your drill and hole saw will last much longer and it will make the job easier.


http://www.tacomascrew.com/Products/Cutting-Fluids/Relton-PNT-A9-A-9-Aluminum-Cutting-Fluid?gclid=CjwKCAjwwPfVBRBiEiwAdkM0HWajAU2MZffUIut9063s4jg8iB_hmw3Ahrqu8B2H2fH8jul2erjKfhoCnvMQAvD_BwE

[chessie4905]

Might be useful if drilling multiple holes. However, probably only ever going to make one hole ever. (Ok,maybe two)

[richard5933]

We have a hole!

It's in the right spot, nothing is spraying up on me, and no electrical sparks are flying. I'll consider this a success.

[richard5933]

Almost there...

[pabusnut]

Richard,

Don't forget to put a piece of fine screen material on the end of that vent to keep the creepy, crawley things out of the bay.
Let's just say it is amazing what can make it through such small spaces!

Steve

[richard5933]

Thanks Steve. I did almost forget that little piece - got it put in there just at the last moment.

[Dave5Cs]

Just saying Forester bits are for Wood, Bi-Metal hole saws are for Metal, aluminum and wood. Cut much better.

https://www.amazon.com/LENOX-Tools-Bi-Metal-Arbored-Technology/dp/B004YK5PBQ/ref=sr_1_5?ie=UTF8&qid=1523218295&sr=8-5&keywords=3+inch+metal+hole+saw&dpID=41YjrWa27ZL&preST=_SX300_QL70_&dpSrc=srch

[richard5933]

That's actually the exact type of hole saw that I used. I was able to locate the hole where the corrugation was at the thin point, so I only had to drill through the plywood interior bay floor and then the aluminum bay floor. The aluminum was thick (two layers), but because the two layers were pressed together the bit didn't have any problem going through.

The battery box components are made out of 1/2" Foam PVC and 1/8"x3/4"x3/4" aluminum angle. The hole saw actually had a more difficult time drilling the hole in the Foam PVC than the floor of the bay. Seems like the heat of the cutting action caused the PVC to gum up a little and bind. Unfortunately I wasn't able to get the lid of the box made from clear acrylic like I planned, as it was too difficult to get hardware mounted to it without cracking since all the mounting points were near the edge.

All in all, it wasn't that difficult and I'm really pleased with the way the box came out.

[richard5933]

Exhaust and battery box are now installed. The digital display is the controller for the exhaust fan so it only runs when charging.

[chessie4905]

Nice, but I hope that fan motor doesn't have brushes. The spark the brushes produce could ignite the hydrogen gas generated while charging.