Have you ever found yourself in a project where you needed a hole to be just a little bit bigger in the metal you were working with, but weren’t sure how to do it without ruining what you had already done?

I know I’ve been there more times than I can count – drilling, dremeling, and filing away hoping that an extra 1/16th of an inch would show up before I went too far. There have definitely been a few projects over the years that ended up in the scrap pile because I took things too far trying to enlarge that confounding hole.

But no more! I’m going to share with you the techniques I’ve picked up over my metalworking career that will allow you to reliably open up holes to the exact size you need without wrecking your work or hurting yourself in the process. By the end of this post on how to make a hole bigger in metal, hole enlargement will be a breeze.

Why Enlarge a Hole in Metal?

First and foremost, why would you need to enlarge a hole in metal? There are many reasons – maybe the material shifted while drilling, or the drill bit broke, or your measurements were off. But no matter the reason, one thing is for sure: having a hole that’s too small can halt progress on your project. So instead of giving up and starting over, let’s learn how to make that hole bigger without any hassle. It’s a skill that will come in handy for any metalworking project you undertake.

Tools Needed

To make a hole bigger in metal, there are a few tools you should have at your disposal. These include:

• A Rotary Tool or Drill With Various-sized Bits
• Files of Different Sizes and Shapes
• A Deburring Tool
• Sandpaper or Emery Cloth

Each of these tools serves a specific purpose in the hole enlargement process, and having them all on hand will make the job easier and more efficient.

11 Step-by-step Guidelines on How to Make a Hole Bigger in Metal

Step 1: Assess the Situation

Before you start drilling or filing away, take a moment to assess the situation. How much bigger does the hole need to be? By how much do you think you’ll need to enlarge it? This will help determine which tool and technique will work best for your specific situation. You don’t want to use a rotary tool if all you need is an extra millimeter of space, as that could end up causing more damage than good.

Step 2: Mark Your Target Area

Once you know the approximate size of the hole, use a marker or punch to clearly mark where you want the enlarged hole to be. This will help guide your tools and ensure that you don’t accidentally enlarge the hole too much or in the wrong spot. It’s always better to have a clear plan before proceeding.

Step 3: Use a Rotary Tool for Small Enlargements

If you only need to enlarge the hole by a millimeter or so, a rotary tool is your best bet. Use a small grinding accessory and carefully grind away at the edges of the hole until it reaches the desired size. Be sure to wear safety glasses and take frequent breaks to avoid overheating the metal. But be careful not to go too far or press too hard – you don’t want a hole that’s too big!

Step 4: Try an Expanding Reamer

If you need to enlarge the hole by more than a millimeter, an expanding reamer is a great option. It works similarly to a drill bit but can create larger holes without needing to switch between various bits. Be sure to use cutting oil and go slowly to avoid putting too much pressure on the tool, which could cause it to snap.

Step 5: Drill in a Spiral Pattern

For larger enlargements, use a drill with that bit slightly smaller than the desired size of the hole. Drill into the metal at an angle in a spiral pattern until you reach the marked target area. Then gradually increase the size of the bit and repeat until you reach your desired hole size. It may require a bit more time and effort, but it’s worth it for precise and controlled hole enlargement.

Step 6: Utilize a Deburring Tool

Once you have enlarged the hole to the desired size, use a deburring tool to smooth out any rough edges or burrs. These can be dangerous if left on sharp metal edges and can also interfere with properly fitting pieces together. Take the time to use a deburring tool for a clean and safe finish. You can also use a small file for this step if you do not have a deburring tool.

Step 7: Use Files for Fine Adjustments

If the hole is still slightly too small, use files of various sizes and shapes to make finer adjustments. Carefully file away at the edges in a circular motion until it reaches the desired size. This step requires a bit more patience and precision, but it is worth it for a perfect fit. It’s always better to take it slow and avoid making the hole too big.

Step 8: Sand Away Imperfections

After using files, there may be small imperfections or roughness on the edges of the hole. Use sandpaper or emery cloth to smooth out these areas for a clean finish. Make sure to use finer grit sandpaper and go slowly to avoid creating any new scratches or imperfections. Otherwise, you may need to start the hole enlargement process all over again.

Step 9: Test Fit

Once you are satisfied with the size and smoothness of the hole, test fit your piece to ensure that it fits snugly. If it’s still too small, repeat any necessary steps until you achieve the perfect fit. It’s always better to double-check before moving on to the next step. You don’t want to have to redo the process because of a small mistake. But don’t worry, practice makes perfect!

Step 10: Clean Up

After successfully enlarging the hole, be sure to clean up your work area and tools. Metal shavings can be sharp and dangerous, so dispose of them properly. Wipe down any tools and work surfaces with a damp cloth to remove any excess debris or debris.  It’s always important to maintain a safe and clean work environment. You don’t want any accidents to occur.

Step 11: Celebrate Your Enlarged Hole!

Congratulations, you’ve successfully learned how to make a hole bigger in metal! It may have taken some time and effort, but now your project can continue without any delays. Remember to take your time and be precise when working with metal – it’s a valuable skill that will come in handy for many future projects.

Following these guidelines and using the right tools, you can easily make any hole bigger in metal without damaging it. Whether you’re a professional metalworker or just completing a DIY project at home, this skill is essential to have. With practice, you will become more proficient at enlarging holes in metal and will be able to take on more challenging projects with confidence. So don’t be afraid to give it a try and see the results for yourself. Happy enlarging! 

Frequently Asked Questions

Q: Can I Use a Regular Drill Bit to Enlarge a Hole in Metal?

A: It is not recommended as it may result in a hole that is too large or uneven. It’s best to use specialized tools for enlarging holes in metal, such as an expanding reamer or rotary tool.

Q: What Type of Metal Can I Enlarge Holes In?

A: This technique can be used on most types of metal, including steel, aluminum, and copper. However, be sure to use the appropriate tools and techniques for each type of metal.

Q: Is It Necessary to Use Cutting Oil?

A: While some may argue that it’s not always necessary, using cutting oil can help prolong the life of your tools and make the process smoother. It’s best to err on the side of caution and use cutting oil when enlarging holes in metal.

Q: Can I Use This Technique on Thin Metal?

A: Yes, this technique can be used on thin metal as long as you use a light touch and take your time to avoid damaging the metal. However, it’s always best to practice on scrap pieces of the same material before attempting to enlarge holes in a project piece.  So go ahead and give it a try!

Conclusion

Whether you prefer the traditional drill and bit method or the tried-and-true hacksaw approach, it’s always important to know how to make a larger hole in metal. As long as you keep safety as your utmost priority and always double-check that you have the correct tools for the job, success will follow. No matter which method you try, remember to go slow when cutting metal so that you can keep the slower speed of your power tool steady.

If done correctly, following the recommendations we’ve provided here today, you’ll be able to fully enjoy the fruits of your labor – that amazing new project with precision cuts! Now it’s time to put your knowledge into action and start drilling those holes and expanding those circles. Keep an eye out for our upcoming post where we’ll show you some more cool tricks on making holes in metal – until then happy drilling! Thanks for reading this article on how to make a hole bigger in metal.