Best method to drill holes

[sjames]

I am going to mount two pop up cleats on the bow of our 2006 SANTE 220. Any advice on the best method to drill the very large holes and not chip the gel coat? I tried on an old ski locker door with a step bit and had good success.

[Super_sport]

Use tape on the gel coat, then mark the location. Measure 3 times, drill once. Use a smaller bit first, then graduate to a larger bit. then I would counter sink the gelcoat a slight amount to avoid pressure on the edge of the gel when the cleat is inserted and tightened. distribute the load of the bolts evenly. Your step bit might be the answer.

[NCH2oSki]

I used a NEW hole saw bit, the exact size needed. Taped the surface with painters masking tape and drilled away. Perfect holes, with no problems.

[sjames]

What type of material was the hole saw tips designed for? Wood, metal etc.

[bchesley]

Rule number one is always run the drill in reverse until you get throught the gel. Then spin it clockwise from there. That is the only way to guarantee that the gel does not chip. Tape is not a guaranteed way to do it even if ou have succeeded on a few holes in the past. Unfortunately I know this from experience. After the hole is drill take a griding bit and bevel the edge along the gel. This will aid in keeping it from cracking in the future.

[mhaaland]

I've used a Roto Zip before and that worked well. Not as precise as a hole saw though.

[ers906]

sjames-
Sounds like you and I are doing a lot of the same projects, you will love the FAE, and as far as drilling into the hull to place popup cleats, this is what i have done the past and it works great.
1. Measure measure measure measure, mark off measure measure measure then maybe cut
2. Tape the gel coat off with painters tape
3. Run the hole saw cut out for each corner (or side) of the hole you want in reverse slowly until you get through hull
4. Use a rotozip tool (or the equivalent) to connect the holes for the desired cut out side (still using the painters tape to cover)
5. Use a dremel sanding rotor tip to create a small bevel along the edge of the cut out to relieve pressure from the gel coat and decrease spider cracks from forming.
6. Place in the recessed cleat, seal with a marine silicone product, etc

Good luck

[sjames]

Yes it does sound like we are getting in to the same projects.
Lot's of good advice on this thread and thanks.

[slob02]

Rule number one is always run the drill in reverse until you get throught the gel. Then spin it clockwise from there. That is the only way to guarantee that the gel does not chip. Tape is not a guaranteed way to do it even if ou have succeeded on a few holes in the past. Unfortunately I know this from experience. After the hole is drill take a griding bit and bevel the edge along the gel. This will aid in keeping it from cracking in the future.

Agreeeeee 100% Reverse first!!

[Super_sport]

Question:

I need a 1- 3/8" hole to make it a snug fit for a 1" thru hull.... I have a 1-1/4" hole saw.. It is only slightly larger hole required to fit... can I take a griding bit and open the hole enough for the 1/8" threads to fit..? grinder bit on a drill should work on fiberglass/gel coat...... for that slight difference?

[Chexi]

I would recommend against this. Do yourself a favor and buy the correct size hole saw if at all possible. I went a little small on one of my intake thru-hulls and it was a nightmare to ground out the hole. I finally got it, but it really really sucked having to do it. The fiberglass is thicker on the bottom though, so it won't be as bad up top, but it will still suck.

[Super_sport]

Chexi, THANKS!! Thats the answer I was looking for.. and the one I was expecting from everyone... I DID find the correct 1-3/8" hole saw at ACE hardware for $6! today, So I dont have to auger the hole out... which I really didnt want to do anyway.

Couple of Beers, Measure three times and DRILL the **** thing! This will be a fun evening! Then Drill the 3 1" vent holes also! four new holes in my boat... I'll take pics!

[sjames]

Holes drilled not to find a big a$* socket

THANKS for all the great advice the hole drilling went great. Had to pucker a bit when the pilot bit goes through and the teeth slam into the gel coat. No nicks and beveled the edges. Not I need to find a **** 1-1/4 deep socket!!! No luck today so far.

[Super_sport]

Looks Great! Pics are great reference...