Teardrops n Tiny Travel Trailers

I've been reading that folks often use a hole saw to cut the round opening in the side of the trailer for electrical inlets and other inlets.

My question is, is it better to cut through the skin only, or to have the insulation and inner plywood in place when the hole is cut? I'm thinking that the extra material behind the skin might stabilize it and make for an easier cut, but, on the other hand, cutting through several layers could possibly make the cutting more difficult. I used the sheets of styrofoam-type insulation.

Which have you tried, and what would you all recommend? This will be my first cut into the skin, and I'm nervous.

Thanks!
Robin

Cutting through the styrofoam insulation and the inside paneling should not be any problem - just make sure you back up the inside wall with a solid piece of wood (at least 1-1/2" thick) clamped or wedged firmly in place against the wall (not hand held) so the paneling won't splinter and the bit makes a clean hole.

Depending on your outside skin and the type of drill you might want to do the same on the outside.

M C

Drill through all of it.. Easiest thing to do is drill from the outside in.. Once the drill bit part of the hole saw is all the way through the wall go on the inside use the small hole for a pilot for the hole saw and drill through what ever is on the inside wall.. If the inside plywood is not up on the walls then don't worry about the inside part and drill all the way through from the outside.. The hole saw will go through the outside skin very easily...

Not to be contrary to previous thoughts (but it is my nature) extend the bit on the hole saw to a bit longer than the thickness of your wall. That will allow the drill to serve as a pilot when drilling and will utilize both inner and outer skill to support it.

If I were "in charge" I'd cut through the thinnest skin first (inside or outside depending on what is thinner). Then the thickness of the material (I'm assuming it s 3/8 or thicker) will guide the saw in addition to the pilot bit.

Using a backing block is a plus but if it's not easy to clamp one in place I wouldn't worry about it. Just go slow as you near breaking through.

I've done this once or twice or so before with no problems. Get a good bi-metallic hole saw. A bit more expensive but it will do a better job and you'll have it for future use on other projects.

Hope this helps.

Cheers,

Gus

I have often wondered why don't people just use floor box recepticals easy to install and you do not have to cut the steel studs in your trailer walls . They will be flush with the floor when your done and they have covers to keep out dirt.

When I do my drilling I use the drill bits for drilling holes into electric boxes for conduits 1/2 & 3/4" drill bits

a Little price at $25-$35 ....but baby they dill "SMOOTH" holes like going into hot butter

something like this

http://www.service.kleintools.com/Tools/PRD/Category/Carbide-Tipped%20Hole%20Cutters%20DRILLBIT-CARBIDECUT/Product/31866

the rear section of the trailer around the door ....is like a tank on my trailer

Good Luck

http://overthetopcargotrailer.blogspot.com/

Thanks, everyone, for the ideas and suggestions! We've decided to go with the "cut through everything at once" method. Now just need to get up the courage to make the cut... Will postpone this by working on the ceiling panels instead.

Robin

I'm with 8ball and Earl, I cut through the side of my CT and then went inside and cut using the hole from the pilot bit. Just make sure you are going in at 90 degrees when you drill and it should work out fine. I was even able to cut the holes for the a/c using this-
Talk about scary, turning that on my baby.

I put off cutting the holes quite a time as well.

Pat

You'll be fine. Yoo might want to make a few practice holes in some scrap to get a feel for the drill / hole saw.

M C

pmowers wrote:I'm with 8ball and Earl, I cut through the side of my CT and then went inside and cut using the hole from the pilot bit. Just make sure you are going in at 90 degrees when you drill and it should work out fine. I was even able to cut the holes for the a/c using this-
Talk about scary, turning that on my baby.

Geez, that looks like some sort of medieval torture device!

Robin Bobula wrote:Geez, that looks like some sort of medieval torture device!

I know, I used a 1/2 drill because it had an extra grip- you should have heard my baby cry when I started cutting the 4 1/2 inch holes through the aluminum skin.
The sad part is, the picture is off of the seller's website- worn cutter, drywall dust and all. I just refused to pay $11 per hole because I could not find the large arbor for my "not quite" hole saw set.
On the other hand, I used that cutter to cut the skin on the trailer, the plywood and FRP interior, even the heavy steel cover of my a/c modification. Not too bad for a $6.99 part.

When I put in electric, I decided not to go through the side. I drilled into the floor up in the very front of the V Nose. I just reach under and pull the plug through. It is the same housing that you'd drill into the side. It works great and is real close to my panel and etc.. I used a keyhole saw in my electric drill to cut through the floor.

Not sure if you can see it well in th epicture. This is an old one.