How to drill the 2" hole for the FUSH kit install

[dieselndixie]

For those that have installed the FUSH kit by ORD, what did you use to "expand" the bushing opening to the 2 inches that it needs?

I know I can grind the rivets and punch out the bolt holes, but the actual opening for the bushing will be larger than the stock opening, and I dont know what to use to enlarge it.

....school me please

 

[76zimmer]

put a one hole saw inside of another. The smaller one (the size of the existing hole) will act as a pilot for the larger one.

 

[ezoliver]

I used an air die grinder with a steel bit. Only took 5 minutes for each side...

 

[K85 Octane]

put a one hole saw inside of another. The smaller one (the size of the existing hole) will act as a pilot for the larger one.

I like that
Was just going to say use some plywood bolted to the holes. The pilot will drill through the wood and keep it centered. You will need to make another for the other side.

 

[pomai]

put a one hole saw inside of another. The smaller one (the size of the existing hole) will act as a pilot for the larger one.

What a good idea, I would have never thought of that, I used a air die grinder but the hole saw sounds like a real good idea which can be used in other similar situations.

I've learned so much from you guys on this web site,
thanks,

Ed

 

[dieselndixie]

yall rock. I had seen the double hole saw before on the forum, but for some reason I didnt think it was for the frame hole cutting

thanks again.

 

[dieselndixie]

Will a cheap bi-metal hole saw kit from harbor freight work? Or does it need to be heavy duty like Dewalt?

 

[NorCal_Chris]

Will a cheap bi-metal hole saw kit from harbor freight work? Or does it need to be heavy duty like Dewalt?

It will work for about 20 seconss. I couldn't even here one to cut through a 55g drum

 

[dieselndixie]

So, would this work?

http://www.amazon.com/DEWALT-D180002-Standard-Electricians-Bi-Metal/dp/B00005LF01

Or, should I just get a couple of steel grinder/file bits for my air die grinder and go that route? It doesnt look like the hole needs to be perfectly round for the mounting bracket to fit.

steel grinder bits are like $6

 

[496truck]

So, would this work?

http://www.amazon.com/DEWALT-D180002-Standard-Electricians-Bi-Metal/dp/B00005LF01

Or, should I just get a couple of steel grinder/file bits for my air die grinder and go that route? It doesnt look like the hole needs to be perfectly round for the mounting bracket to fit.

steel grinder bits are like $6

Sounds like you just answered your own question.

You already own the die grinder, bits are cheap... see where I'm going with this?

 

[dieselndixie]

yeah, im with ya. I just like to hear the brethern say it...makes me feel better