It is sheer butchery but I did it to a set of Audi Turbo wheels when I
wanted to use them on a 2wd for a trip deep into Mexico. The Load C
Michelin tires were fairly worn already from the wheels being used first
on my Syncro and I was ready to switch to other wheels after the
trip.The wheels were more or less ruined by this drilling since the
center hole needs to be precise for modern tire balancing machines to
spin them true. I did it to 3 of a set of 5 so the spare could fit on
the front or back. Only the front wheels needed to be opened up.

I cut a piece of plywood to fit inside the wheel. I bolted it to the lug
holes and then drilled a pilot hole down from the front side with a long
bit. This became the guide hole for the hole saw center bit into the
back side of the plywood. The big hole in the plywood acts as a guide
for the hole saw to continue into the metal. I did it by hand held 1/2"
chuck drill motor.

Mark

Tabe Johnson wrote:
> Being a cheap bas---, oh, I mean "Value Driven", I wanna cut the hubs in my alloy wheels to fit the Vanagon centerbore myself.  Has anyone ever cut thick aluminum (wheels?) with a bimetallic hole saw?
>
> If not, I'm gonna get me a cheap test alloy wheel and try cutting it to see what happens.
>
>
> tabe johnson/87 westy
>
>
>