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what to use to drill into headlight housing

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Kevin_S

Joined: Jul 20 2003
Posts: 2809
Location: WV


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Post Wed Sep 12, 2007 9:45 am

I know the obvious answer here will be "drill" -- I'm not dumb.

I have a set of Whelens and I need to drill a 1" hole. I was wondering what type of bit you guys recommended. If this were a smaller hole, I wouldn't even stop to think about it ....it's just a 1" hole into an expensive piece of plastic worries me, ya know?

I was thinking one of those bits that are used to drill doorknob holes (you can tell I'm a carpenter ...i don't know the fancy name for it lmao)
...sound good to you guys or did you use something else?
justin

Joined: Jan 15 2004
Posts: 5061
Location: Madison


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Post Wed Sep 12, 2007 9:49 am

not done it myself, but im pretty sure you are correct by using a hole saw.

i REALLY wanted to respond by saying drill, but you covered yourself, good job icon_smile.gif
Tim

Joined: Nov 16 2003
Posts: 10795
Location: Kalamazoo, MI


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Post Wed Sep 12, 2007 10:23 am

User posted image
justin

Joined: Jan 15 2004
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Post Wed Sep 12, 2007 10:30 am

^ mmmmm hole saw.
mx107marlin

Joined: Aug 12 2007
Posts: 3095
Location: Fairborn, OH


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Post Wed Sep 12, 2007 11:05 am

I drilled a 3/8" hole in the headlight housing with a standard steel bit, high speed, using just a little pressure....I would still do that with the hole saw, use it at fairly high speed with very little or no pressure.

I'm not an expert though, just stating my experience. Seems to leave a cleaner cut.
Aken

Joined: Feb 12 2003
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Post Wed Sep 12, 2007 11:27 am

I used one that looks like this:

Just drilled a small guide hole in the center, and went to town.


Last edited by Aken on Wed Sep 12, 2007 11:38 am, edited 1 time in total
kornholio788

Joined: May 02 2005
Posts: 9748
Location: Tosa, WI


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Post Wed Sep 12, 2007 11:29 am

yaaa he fixed it...i would say a whole saw would work best..and yes as stated before high speed with a little pressure works great..gives a smoother cut and cuts it more evenly
Kevin_S

Joined: Jul 20 2003
Posts: 2809
Location: WV


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Post Wed Sep 12, 2007 11:45 am

Aken wrote:
I used one that looks like this:



Just drilled a small guide hole in the center, and went to town.

I used one like that to drill through some plexiglass -- wasn't a pretty finished product.

That's why I'm leaning towards the door knob thing lol.

But plexi is different from reg. plastic. I dunno. I'll try the saw first (because I already have one) and if i screw up, i'll use aken's idea.
corvettecrazy

Joined: Dec 17 2003
Posts: 4357
Location: moved (twice)


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Post Wed Sep 12, 2007 11:59 am

Tim wrote:
User posted image


X2
clutch1

Joined: Oct 08 2006
Posts: 1928
Location: around hurr.


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Post Wed Sep 12, 2007 12:26 pm

Just don't use one of those flat wide wood-bits. It gets hung up and cracks stuff.
Aken

Joined: Feb 12 2003
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Post Wed Sep 12, 2007 12:29 pm

Worked fine for me. *shrug*
clutch1

Joined: Oct 08 2006
Posts: 1928
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Post Wed Sep 12, 2007 12:34 pm

Really? I have no end of issues if I drill through anything but wood or other soft stuff with them!
Prolly just cause you have mad ninja skills!
Aken

Joined: Feb 12 2003
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Post Wed Sep 12, 2007 12:37 pm

Must be, hah.

I'd go with the red hole bit thing above since thats what most recommend. I just got lucky probably.
mx107marlin

Joined: Aug 12 2007
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Location: Fairborn, OH


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Post Wed Sep 12, 2007 12:37 pm

Alright....I'm confused, what exactly was Aken's idea?....I can't view the image; Because "Hotlinking is uncool."

While we're on topic, any ideas what's best to small pilot holes to tap screws though in plexi? Or best to cut thin plexi period?
Moss

Joined: Mar 23 2004
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Post Wed Sep 12, 2007 1:04 pm

i was thinking dremel.
clutch1

Joined: Oct 08 2006
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Post Wed Sep 12, 2007 1:11 pm

If me an Aken are on the same page this is the bit we're talking about
User posted image
Dave

Joined: Aug 22 2006
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Post Wed Sep 12, 2007 1:17 pm

User posted image

Worked for me. icon_razz.gif
Kevin_S

Joined: Jul 20 2003
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Post Wed Sep 12, 2007 1:35 pm

I don't want it to look like **** when I'm finished.
Cooper

Joined: Mar 19 2006
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Post Wed Sep 12, 2007 2:33 pm

Jesus .. is that the first soldering iron every made, Dave ?
mx107marlin

Joined: Aug 12 2007
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Post Wed Sep 12, 2007 3:00 pm

Cooper wrote:
Jesus .. is that the first soldering iron every made, Dave ?


The third one looks like a cheap screwdriver mated with an iron.
Dave

Joined: Aug 22 2006
Posts: 176
Location: CT


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Post Wed Sep 12, 2007 3:12 pm

Cooper wrote:
Jesus .. is that the first soldering iron every made, Dave ?


Hey hey HEY, your mom likes the one on the far right =P


haha, but yeah, it's an oldie, got it from my grandfather's old machine shop before he sold it. Still works just as good as the rest of them out there, so there's no need to buy anything new, imo.
mx107marlin

Joined: Aug 12 2007
Posts: 3095
Location: Fairborn, OH


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Post Wed Sep 12, 2007 3:50 pm

Dave wrote:
Still works just as good as the rest of them out there, so there's no need to buy anything new, imo.


Very true....why replace anything old if it doesn't need it


Last edited by mx107marlin on Wed Sep 12, 2007 4:07 pm, edited 1 time in total
justin

Joined: Jan 15 2004
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Post Wed Sep 12, 2007 4:07 pm

clutch1 wrote:
If me an Aken are on the same page this is the bit we're talking about
User posted image


i do believe that is a bit intended for wood. your results may not be that great.
clutch1

Joined: Oct 08 2006
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Post Wed Sep 12, 2007 5:56 pm

justin wrote:
clutch1 wrote:
If me an Aken are on the same page this is the bit we're talking about
*bit pic*


i do believe that is a bit intended for wood. your results may not be that great.


Lol, I know, read my posts icon_lol.gif
Tat2Dragons

Joined: Jan 21 2007
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Post Wed Sep 12, 2007 7:15 pm

clutch1 wrote:
If me an Aken are on the same page this is the bit we're talking about
User posted image


Those actually work great for cutting holes into plastic.I like to use them when I drill holes for switches,it gives a nice clean cut. icon_smile.gif
The_Mastor

Joined: Jan 23 2006
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Post Wed Sep 12, 2007 7:22 pm

Tim wrote:
User posted image


That is your winner. It is what I used and made some mighty perfect holes icon_biggrin.gif
Chris

Joined: Sep 27 2004
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Post Wed Sep 12, 2007 8:40 pm

Tat2Dragons wrote:
clutch1 wrote:
If me an Aken are on the same page this is the bit we're talking about
User posted image


Those actually work great for cutting holes into plastic.I like to use them when I drill holes for switches,it gives a nice clean cut. icon_smile.gif


x4
A-Ray

Joined: May 01 2005
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Post Thu Sep 13, 2007 7:35 am

Chris wrote:
Tat2Dragons wrote:
clutch1 wrote:
If me an Aken are on the same page this is the bit we're talking about
User posted image


Those actually work great for cutting holes into plastic.I like to use them when I drill holes for switches,it gives a nice clean cut. icon_smile.gif


x4


That is the exact same style bit that jdusty and I used to put whelen strobes in my headlights. We drilled a small pilot hole with a regular bit then used that bit to get the 1" hole. Worked like a charm.
Kevin_S

Joined: Jul 20 2003
Posts: 2809
Location: WV


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Post Thu Sep 13, 2007 7:41 am

Everyone who has done it recommends Aken's bit.

Everyone else says use the hole saw.

I guess that settles it.

I'm gonna go buy one of those. The cheapest I've seen em was like $14.99 at Lowes, though. damn.

The hole saw is like 3.99 lol
TRogers

Joined: Feb 09 2005
Posts: 6083
Location: Ohio


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Post Thu Sep 13, 2007 7:53 am

I can't see Aken's picture but if he posted a uni-bit. Kudos.

User posted image



That is the best thing to use, hands down. I love step down bits. (uni bits)
mx107marlin

Joined: Aug 12 2007
Posts: 3095
Location: Fairborn, OH


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Post Thu Sep 13, 2007 8:14 am

Always wondered what those were called....definitely need to get my hands on a set of those.... They look like the work really well.
The_Mastor

Joined: Jan 23 2006
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Post Thu Sep 13, 2007 5:22 pm

I've done it and I didn't recommend Aken's bit... icon_confused.gif
Aken

Joined: Feb 12 2003
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Post Thu Sep 13, 2007 5:38 pm

Uni bit FTW. If I had one of those I would've used it, but I was impatient and used the resources I had available (AKA the bit I and others mentioned).
The_Mastor

Joined: Jan 23 2006
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Location: Idaho


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Post Thu Sep 13, 2007 5:53 pm

That one Rogers posted looks like a winner.
TRogers

Joined: Feb 09 2005
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Post Fri Sep 14, 2007 5:56 am

I use Uni-bits on metal, plastic, wood, human skulls, etc. If you have a set of different sizes, no size hole should ever be a problem. I really adore them. icon_biggrin.gif
kornholio788

Joined: May 02 2005
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Location: Tosa, WI


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Post Fri Sep 14, 2007 7:58 am

TRogers wrote:
I use Uni-bits on metal, plastic, wood, human skulls, etc. If you have a set of different sizes, no size hole should ever be a problem. I really adore them. icon_biggrin.gif

"reminds myslef to never **** off TRogers"

...i have one sittin in my garage new in the package..cant wait to use it...
TRogers

Joined: Feb 09 2005
Posts: 6083
Location: Ohio


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Post Fri Sep 14, 2007 9:37 am

My italian blood brings out the worst in me. Ball pin hammer to your knuckles, and stuff like that. I can go all day.
Kevin_S

Joined: Jul 20 2003
Posts: 2809
Location: WV


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Post Fri Sep 14, 2007 5:48 pm

So I used the hole saw and it worked perfectly. However, due to the way my headlight is shaped, I had some trouble gettin a flush mount on my drivers side (learned from my mistake and got it pretty good on the passenger side)...consequently, there's a tiny bit of moisture in the driver's lamp. gonna take it back out tomorrow and try to dry it out then seal it up again really well.

Anyway -- these sumbitches are bright haha...maybe too bright. It REALLY amazed me when I threw power to em. wow.
04yellowf150

Joined: Feb 11 2006
Posts: 1282
Location: West Virginia


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Post Fri Sep 14, 2007 8:48 pm

i reccomend the uni bit, used it on plastic and such when i worked at the shop
thefiredogg

Joined: Jan 27 2004
Posts: 571
Location: Cleveland Ohio


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Post Sat Sep 15, 2007 4:10 pm

make sure when ur done putting a hole in it, get all the shavings and crap out of your headlight. otherwise it looks like ****.....
Kevin_S

Joined: Jul 20 2003
Posts: 2809
Location: WV


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Post Sat Sep 15, 2007 4:25 pm

yeah...i worked for like 30 minutes on each light getting as much as i could out...there's still a tiny bit left but it's hardly noticable.

PITA
Kevin_S

Joined: Jul 20 2003
Posts: 2809
Location: WV


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Post Wed Sep 19, 2007 5:13 pm

video:
http://mozunkhost.com/RickJamesIsMyHero/P1010164.MOV

sorry for the quality. I don't have a camcorder.
That video pork posted like a year ago of the car club he and aken were (are?) in shows em better.
Radioflyer

Joined: Sep 25 2007
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Post Tue Sep 25, 2007 7:11 pm

Actually, a solder gun (woodburner style) works very well. I've used them on many thing plastic where a drill ran the risk of cracking. It also reduces the risk of injury since most headlight housings don't lend themselves well to clamps. (just remember a mask and a fan)
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