enlarge existing hole in metal panelling

[Rockingit]

On a serious note, depending on how thick the material is that you need to cut, maybe a Dremel could work?

Of course, I notice that no-one has yet suggested doing it the old way with a stitch drill.....

 

[timhoward]

Of course, I notice that no-one has yet suggested doing it the old way with a stitch drill.....

I thought stitch drilling is the same as "using a smaller hole saw multiple times", or is there something handy to learn here?

 

[westward10]

Metal nibbler?

 

[nicebutdim]

Decent quality holesaws are available in 160mm for much more reasonable prices, but you stand a good chance of pulling the gearbox out of a drill or breaking a wrist using them to cut sheet steel.

Nibbler by far the best option.

 

[Baddegg]

Angle grinder or stitch drill and file would be my way…..although I have a 160mm hole saw so I’d probably use that

 

[buzzlightyear]

Angle grinder or stitch drill and file would be my way…..although I have a 160mm hole saw so I’d probably use that to get out of prison

Drop a file in cake next time.

 

[brianmoooore]

Good old fashioned adjustable tank cutter. These were used for cutting holes in steel water tanks, and mine probably dates back to the '50s, but they are still available new.
They need a well located pilot hole, so you'd have to 'fill' the original hole first. This could be a 100mm long piece of thin steel bar, pop riveted across each hole in turn.

 

[Jim_e_Jib]

Definitely a metal nibbler:

Makita JN1601 Nibbler (230V) - Machine Mart - Machine Mart

www.machinemart.co.uk

You could cut a hole for a sunroof in your Ford Escort whilst you're at it

 

[OnlQQker]

Any good?

40-200mm Adjustable Hole Cutter with Cowling - https://www.cef.co.uk/catalogue/products/1039966-40-200mm-adjustable-hole-cutter-with-cowling?gclid=bca419f89b2e1fff3e627b5bfa2b7a8f&gclsrc=3p.ds&msclkid=bca419f89b2e1fff3e627b5bfa2b7a8f

 

[DPG]

Any good?

40-200mm Adjustable Hole Cutter with Cowling - https://www.cef.co.uk/catalogue/products/1039966-40-200mm-adjustable-hole-cutter-with-cowling?gclid=bca419f89b2e1fff3e627b5bfa2b7a8f&gclsrc=3p.ds&msclkid=bca419f89b2e1fff3e627b5bfa2b7a8f

Pretty much the same as the tank cutter that Brian was on about.

 

[OnlQQker]

Pretty much the same as the tank cutter that Brian was on about.

They're a great tool as long as you make sure the outer blades are lined up and everything is tight. I have a strong feeling the guard isn't stopping the dust, it stops the bits flying out and hitting you because they are loose.

Grey tool for cutting through Mdf/ply for the pan connector to pass through for built in toilets!

 

[brianmoooore]

Any good?

40-200mm Adjustable Hole Cutter with Cowling - https://www.cef.co.uk/catalogue/products/1039966-40-200mm-adjustable-hole-cutter-with-cowling?gclid=bca419f89b2e1fff3e627b5bfa2b7a8f&gclsrc=3p.ds&msclkid=bca419f89b2e1fff3e627b5bfa2b7a8f

What's the material being cut? This one's not rated for steel.