How to Cut Holes in Fiberglass

Using a Hole Saw

• 1

  Put on gloves, a long-sleeved shirt, goggles and a dust mask to protect yourself from fiberglass dust and shards.

• 2

  Clamp the fiberglass in place if needed.

• 3

  Drill a 1/8-inch pilot hole through the fiberglass at the center of the intended hole. Drill slowly, applying steady pressure and allowing the bit to set the pace. Trying to force the drill to go faster may crack the fiberglass.

• 4

  Replace the drill bit with a fine-toothed hole saw in the required diameter. Tighten the drill's chuck as securely as you can.

• 5

  Place the hole saw's center bit against the pilot hole. This will prevent the bit from skipping across the fiberglass surface.

• 6

  Bore a hole through the fiberglass, working slowly and applying steady pressure until the hole saw cuts all the way through.

• 7

  Sand any rough edges. Begin with 100-grit sandpaper, then resand with 200-grit, than 300-grit until the smoothness you require has been reached.

Using a Jig Saw

• 8

  Don safety clothing.

• 9

  Draw the circle you require onto the fiberglass using a marker.

• 10

  Clamp the fiberglass in place, if needed.

• 11

  Drill a 1/8-inch pilot hole inside the circle, close to the marker line but not actually touching it.

• 12

  Enlarge the hole with a drill bit that is slightly larger than your jigsaw's blade.

• 13

  Insert a fine-toothed blade designed for fiberglass into your jigsaw. The teeth should be facing forward.

• 14

  Set the fiberglass surface so it is horizontal, if possible. This will make control of the saw easier.

• 15

  Insert the jigsaw blade into the drilled hole.

• 16

  Pull the drill's trigger to activate the saw.

• 17

  Slowly drill forward from the hole, angling the cut so it meets the marker line.

• 18

  Saw out the hole, following the marker line. Move the saw forward very slowly to maintain the highest amount of control.

• 19

  Sand the edges of the hole as needed.