I don’t use hole saws and the like; I’ve found a much better and faster way to do this. Most pods like the Navpod series have basically a round hole for wire entry; but the pod itself covers a much larger area of the tubing. As some of the connectors don’t turn a 90° angle when exiting the tubing, I’ve found it much easier to cut an elongated hole in the tubing without the pod mounted, pass all the wiring through that hole, THEN pass the wires into the pod and mount it.
The way I cut the hole is to use the cheap grinding wheels on my Handy Dremel Tool (to use Wal’s moniker…). I make two angled cuts for the top and bottom of the hole, then cut straight sides, like in this drawing: http://www.postaudio.net/webserver/Navpodcutout.pdf <http://www.postaudio.net/webserver/Navpodcutout.pdf> This makes it much easier to get all those connectors and wiring through the guard into a pod. Also, make sure to pull the cables with the largest connectors first, so you don’t fill the guard tubing with lots of wires, then have to try to stuff a large connector through, too. — Fred Fred Street -- Minneapolis S/V Oceanis (1979 C&C Landfall 38) -- Bayfield, WI > On Jun 28, 2016, at 10:58 AM, Marek Dziedzic via CnC-List > <cnc-list@cnc-list.com> wrote: > > With a large connector, you will have to cut an elongated hole, even in a > larger diameter guard, because the connector would not bend. > > Drilling through the SS pedestal guard is a pain. You better have good tools > and know how to do that (in one word – slow). A good hole saw (e.g. Milwaukee > bi-metal (https://www.milwaukeetool.ca/accessories/drilling/49-56-9662 > <https://www.milwaukeetool.ca/accessories/drilling/49-56-9662>)) and a > tungsten cutter (e.g. > https://www.dremel.com/en-ca/Accessories/Pages/ProductDetail.aspx?pid=9901 > <https://www.dremel.com/en-ca/Accessories/Pages/ProductDetail.aspx?pid=9901>) > would be your friends (and a good investment).
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