Cutting Holes In Aluminum Soffit For Can Lights

buckeyeso2

any hints for this. Our can lights measure approx. 6 5/8" . I usually just use a snips, but wondered if a hole saw would work? Or maybe a dremel with a cirlcle cutting attachment? thanks

neolitic

If you're not doing 100, one of those
cheap drywall circle cutters ought to
cut light gauge aluminum.

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tool junkie

Thats what I would do. You can also use a jigsaw.

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MALCO.New.York

Use a jigsaw and leave tell-tale marks from the foot.

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Ultimate Wisdom---------
http://www.youtube.com/watch?v=OW-cnizLDEE

KHouse75

I make a template, run a sheetrock knike around is a couple of times then drill a hole next to the cut, take a pair of pliars and pull out the circle.

It works pretty much like when you open an aluminum can.

tool junkie

Nahhh, not at all. I'll share an old trick with you but I think everyone else already knows this... foam tape on the foot, or even just a couple layers of masking tape. No marks at all.

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neolitic

...or blue tape on the work piece.

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tool junkie

better yet

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MALCO.New.York

Blue masking works well.

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Ultimate Wisdom---------
http://www.youtube.com/watch?v=OW-cnizLDEE

Grumpy

Personally I'd use a bi-metal hole saw.

neolitic

Where did you get yours?
The largest I've seen was a 6" Morse,
and that sucker was @ $130!

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Grumpy

Price for me wouldn't be a concern as I'd simply mark it into the job cost, and you'd probably have a huge labor savings. I've never needed to get one that large but I just did a little research: http://cgi.ebay.com/NEW-6-Hole-Saw-f...QQcmdZViewItem

http://cgi.ebay.com/ADJUSTABLE-HOLE-...QQcmdZViewItem

If you can imagine it, it's probably already on Ebay.

They should use that slogan and pay me royalties!

Here are some more: http://www.toolsdirect.com/index.cfm...&source=ptyhpi

http://www.service.kleintools.com/cg...D(A0150):31606


I'm not electrician, but would think if 6 5/8" were a common sized can light that there would be a vast array of hole saw availability in that size. And I was right, they seem to be marketed to electricians: http://www.electricsupplyonline.com/...-hole_saws.php

neolitic

That one is basically what I was taking about.
http://cgi.ebay.com/ADJUSTABLE-HOLE-...QQcmdZViewItem

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mdshunk

The 6-5/8" hole saws are a stock item at my electrical supply houses, in both Greenlee and Lennox. The grit hole saw works better in aluminum soffet, since the teeth of the regular hole saw get really "grabby" with a cutter that big. You can run it in reverse for smoother action. I've used a RotoZip with equally good results.

neolitic

Seems to me that Sparkys are
the only guys that use one
often enough to make it
worth while for a dedicated size.

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mdshunk

The Greenlee grit one is 65 dollars. 6-5/8 is a very popular size for many recessed cans. 6-3/8 is another popular one.

house bldr

roto zip with a circle cutter attachment works great, I use it all the time

JonM

tool junkie

I need one of those...

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