Any tips for cutting a hole in diamond plate?

Michigan_Mike

I would like to install a marine grade cigarette style plug on the side of my diamond plate tub on the front of the trailer.  I have used the Greenlee hydraulic hole punch tools in the past when I was doing line work, but am wondering if there is another means of cutting a decent hole in the diamond plate?  I'm not certain the Greenlee is intended for DP anyway, but short of drilling multiple, smaller holes with a battery operated drill and finishing the cutting with a jig saw I would ask first before calling my buddy in the Home Depot tool rental area....  Thanks!

Tabaz

I used a 3/4" step drill from Harbor Freight (The Happiest Place on Earth) to drill a hole for a lock.  Went through the diamond plate like butter.

Verna

I had the welder drill the hole for my 2nd Zamp plug for my ARB when he reworked the tub for two batteries.

Ratkity

I must have had thin diamond plate for replacing the front plastic propane box because I just used tin snips to cut out a big square (after drilling large corner holes to start off). I know some of that diamond plate is thick.

Verna

Actually, the diamond plate is the thin kind. Since the welder was working inside his shop, I just asked him if he would drill the hole for me. I have mostly woodworking drill bits at home, and it was just easier.

Mike, if you have the correct size of drill bit, it's just like drilling into any aluminum, such as when I drilled the hole into the side of my aluminum sided Silver Shadow for the ARB plug. 

RZRBUG

OutbackAZ said:

I used a 3/4" step drill from Harbor Freight (The Happiest Place on Earth) to drill a hole for a lock.  Went through the diamond plate like butter.

Should be able to find one large enough at Home Depot.

Michigan_Mike

I'll head up to Home Depot today and look around.  I did Google in some tips yesterday and some folks mentioned hole saws.  Since aluminum is soft it does collect on the blade and a few individuals suggested using cutting oil during the process too and cleaning the blade.  Thanks for all the tips and I will look at the but you posted up too Larry as I have looked at them for quite a while but don't have one "yet."  

jkjenn

Michigan_Mike said:

I'll head up to Home Depot today and look around.  I did Google in some tips yesterday and some folks mentioned hole saws.  Since aluminum is soft it does collect on the blade and a few individuals suggested using cutting oil during the process too and cleaning the blade.  Thanks for all the tips and I will look at the but you posted up too Larry as I have looked at them for quite a while but don't have one "yet."  

My friend helped me line install my battery box platform onto the tongue and we used regular oil when we drilled into the tongue.