"Magnusfarce" wrote in message
...
Just got a replacement front door, the usual Stanley steel type. I want
to
put one of the oversized peepholes in it that rquires a 1 inch hole. What
is the best way to make such a hole? I'm assuming the good old spade bit
won't work, and my little cup saw/drills won't like the metal either. Any
advice?

How big is the lip around the edge of the peephole? Proper answer is to go
to the industrial supply and get a proper hole saw for metal (or even just a
1-inch bit, if they carry them that big), but for a one-time job, that is
probably pretty expensive. I'd carefully lay out and scribe the hole, from
both sides, and drill lotsa tiny holes inside the scribe line. Drill a pilot
hole all the way through, to keep your centers lined up. Eventually, you
will get it to the point you can pop it out of there, and clean up the hole
with a file. The skin metal on a residential-grade door is thinner than a
car fender, in most cases. Use sharp bits, and try not to lean on the door
as you work- center section of most cheap steel doors is just filled with
foam, and it is easy to make things look like a crushed and straightened
beer can. Recommend one of those collar things on the drill, or even a
pre-drilled block of wood to use as a jig, to keep bit perpendicular to the
plane of the door.

aem sends....