David Lesher wrote:
A friend asked:

Need to cut a few (=6) 5.5" holes (actually 140mm, but that
is 5.51", so close enough) in 1mm sheet metal (carbon steel, I
think).

2 side by side holes initially in a roughly 20"x17" piece of 1mm
cold rolled steel with one finished side. May need to put holes
in 2 similar pieces of sheet metal later on.

I thought:
HF has a flycutter with a carbide tip...
http://www.harborfreight.com/carbide-tip-adjustable-circle-cutter-68117.html

The 'Large Print' says that one tops out at 5" diameter
(as you imply).

That, a longer arm& a drill press...

Consider one of these:

http://www.tools-plus.com/malco-hc1.html

I see that HF no longer lists their clone, the
'Adjustable sheet metal hole cutter' model 97645.
http://www.harborfreight.com/manuals...7999/97645.pdf

I'm considering ordering replacement parts for mine:

Item Description Qty

2 CAP w/BEARING (NSK 965 V2) 1
4 BIT (M730-2) 4-3/8"L x 3/16" 3
6 SPACER w/SET SCREW 1
8 HEX WRENCH 3mm 1
9 BOTTOM BEARING 1
10 SHOE PLATE 1
11 SCREWS FOR SHOE PLATE (Set)
12 PIVOT PIN 1
13 PIVOT PIN NUT 1
14 GRAY DIE-CAST HANDLE/BODY 1

Call 1-800-444-3353, Monday thru Friday,
6:00 am to 4:30 pm PST
http://www.harborfreight.com/contact-customer-service
Harbor Freight Customer Service,
3491 Mission Oaks Blvd., Camarillo, CA 93011-5034.


Oh Yaasss.


--Winston