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by **RunsWithCrouse-Hinds** on Wed Jul 24, 2013 6:58 pm

Hi all, I'm getting closer to getting all the parts together for my backyard pole setup, and this will require that I drill a hole that is about 2" in diameter in the side of the pole for the controller condulet. Given the the pole itself is round, I'm not exactly sure how to do this. I'd rather not use a saw all since the hole would not likely end up bring all that round in the end, but I'm also leery of using a hole saw on a non flat surface. Any advice?

by **jab8356** on Wed Jul 24, 2013 7:00 pm

Take it to a machine shop and get them to do it.

by **RunsWithCrouse-Hinds** on Wed Jul 24, 2013 7:05 pm

Machine shop may not be an option... Pole is already mounted!

by **jab8356** on Wed Jul 24, 2013 7:08 pm

Drilling a 2" diameter hole in anything metal without a drill press is going to be a real challenge!

by **EPAC-EPIC-MARC** on Wed Jul 24, 2013 7:18 pm

I drilled large holes in most of my poles for wire to run out the bottom and along the floor molding. It is a pain to drill into the metal. I usually hold the pole pipe in a vice and first pound a divot to keep the bit from bouncing around. I start with a smaller bit and allow the bit to cool off periodically. Once I'm through I use a larger bit to drill the large hole.

For a larger hole you may want to first use a smaller bit, then a metal boring bit to finish it off

My 2 cents...

by **BigTbird1974** on Wed Jul 24, 2013 7:24 pm

The guys installing the (cast iron) fire sprinkler plumbing under the stage in a new church I worked in recently were using a large hole-saw, but they also had some kinda heavy clamp-on 'guide' to help keep the likewise very large power drill driving it all from breaking their arms during the process. Even with that, there was the occasional "<BANG><curse><curse>"... :shock:

by **somuchtoseeanddo** on Wed Jul 24, 2013 7:36 pm

Would first drilling, say a 1/4" to 1/2" hole then a 1"er then your 2" work?

by **TacomaJoe** on Wed Jul 24, 2013 7:42 pm

Hole saw. It's 1/4" pilot bit will hold it steady. Be careful when the first teeth hit, too fast and the teeth will grab and break the pilot.

by **Macsignals** on Wed Jul 24, 2013 8:17 pm

TacomaJoe wrote:Hole saw. It's 1/4" pilot bit will hold it steady. Be careful when the first teeth hit, too fast and the teeth will grab and break the pilot.

I'm with Joe, get a decent arbor, bit and hole saw and go to town. Keep it oiled as you're cutting and keep it around the recommended speed.

by **2070** on Wed Jul 24, 2013 8:21 pm

RunsWithCrouse-Hinds wrote:Machine shop may not be an option... Pole is already mounted!

A 2" Hole saw with a cordless drill works well!!!

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