Panel knock put punches and hole saws work well for holes that are arenít too big but it gets harder and more expensive as the size of the hole increases.
You can cut holes with a router but cutting holes with a router is a cumbersome ordeal. The router is really just too big a tool to be swinging 360 degrees easily. You can set it to cut holes down to around 1.5 inches and up to around 10 inches. The toolís small size allows you to easily see your work as you are cutting. If you want an arc you can start and stop anywhere you want. It will cut any thickness of sheet aluminum.
The cutting speed in 032 thick 2024-T3 aluminum is around 40 inches per minute so you can cut a 4-inch diameter hole in less than 20 seconds.
Please note, Aircraft Spruce's personnel are not certified aircraft mechanics and can only provide general support and ideas, which should not be relied upon or implemented in lieu of consulting an A&P or other qualified technician. Aircraft Spruce assumes no responsibility or liability for any issue or problem which may arise from any repair, modification or other work done from this knowledge base. Any product eligibility information provided here is based on general application guides and we recommend always referring to your specific aircraft parts manual, the parts manufacturer or consulting with a qualified mechanic.
Per the vendor it could but it was not designed for stainless and it is not recommended.
Yes. It comes ready to use out of the box - the router bit is double-ended.
We can special order them from the manufacturer. Please contact our sales department for pricing and lead time.
Typically, people use the this at about 90 PSI which gives 3 CFM of air consumption.