Thread: Cutting cast aluminum with a hole saw???

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....can I cut a hole in my cast aluminum Edelbrock valve covers with a hole saw??? Or is cast aluminum like cast iron??? THANKS, Bill

I think so , I also thought you could cut cast iron with a hole saw too?

.....Ok, Thanks ... I guess I'm mistaken on cutting cast iron, anyway my valve covers are cast aluminum so I'm headed out to try it...... thanks again, Bill

you need to watch out hole saw cut big you are better off with a step drill or a carbide hole cutter no run out to make the hole bigger.the center drill in the hole saw can add to run out. drill were you want the hole with a 1/4 drill then run a 1/4 drill rod or cut the head off a long bolt and put it were you would run the 1/4 drill bit in the hole saw. this will help some but it will still cut big

Use lots of stick wax lube and clear the chips often. low speed cuts are a lot cleaner than fast ones. Keep spindle length as short as possible. Dont even think about freehanding them. Quick way to have junk valve covers. This isn't going to work if you are trying to make the hole bigger. use a step bit or find someone with a mill.

....Thanks Pat, Thanks 61Bone, I'll get a step drill as I found one for a good price {$25 bucks}. The carbide cutter was $75! BUT before I get it I took an old metal valve cover & drilled it out to 1 3/8" & put my new baffle in. I want to make sure it doesn't leak oil before drilling the aluminum ones. That's what the 1 3/8" hole in the valve cover was all about; to install a baffle..... Bill

Originally Posted by billlsbird

....Thanks Pat, Thanks 61Bone, I'll get a step drill as I found one for a good price {$25 bucks}. The carbide cutter was $75! BUT before I get it I took an old metal valve cover & drilled it out to 1 3/8" & put my new baffle in. I want to make sure it doesn't leak oil before drilling the aluminum ones. That's what the 1 3/8" hole in the valve cover was all about; to install a baffle..... Bill

i see alot of valve cover that leak were the hole was to big

LOL.... well, the baffle seems to work so I'll order the step drill .....