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How to Cut a Grommet Hole for Installation of the Oval Trailer Tail Lights # STL22RB  

Updated 02/20/2012 | Published 02/14/2012



Question:

what is the best and cleanest way to cut the oval holes for trailer lights in metal?I dont have access to a gas cutter.

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Expert Reply:

The easiest way to cut the oval hole for the Rubber Grommet, # a70gb, in my opinion, would be to use a Light Mounting Bracket for 6-1/2 inch Oval Trailer Lights, BK70BB, as a template and then use a hole saw the correct size to cut a hole on each end of the mounting location. Then, use a angle grinder with cut off wheel or a reciprocating saw with metal cutting blade to cut the straight top and bottom sides of the hole.

The correct width for the grommet is 2-5/8 inches, but I have found that a 2-1/2 inch hole saw usually works well and you could enlarge the hole slightly with a file or small rotary tool with grinding stone. When drilling the holes make sure that the outside edge of each hole is 6-3/4 inches apart.

I produced a short video, see link showing a 2-1/2 inch hole saw and the mounting bracket I mentioned.

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Bob G
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