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One More Clearance Lamp Question--Punching the Holes

Discussion in 'Ford Trucks' started by Ron G, Dec 8, 2007.

  1. I bought the lamps, the wiring harness, and the special nuts that hold the lamps in place from my local Ford dealer this week. I also bought a Greenlee slugbuster knockout punch set for 1/2" conduit, that Greenlee says will make a .89" hole (just a shade bigger than the 7/8" (.875) hole required). Maybe there are a couple of electricians here that have used these punch sets for making holes in unpunched electrical boxes or someone else that has used them. Is this the right tool for the job ??? Greenlee says that this punch can handle 10 gauge or 3.5 millimeter steel. 3.5 mm is awfully thick--it's about 1/8 inch. I don't think that the sheet metal on my 2003 F-250 is even near 1/8 inch thick.

    So, will this punch do the job, or should I have gotten a 7/8" radio chassis Greenlee punch ????

  2. deckboys

    deckboys Senior Member
    Messages: 198

    shouldn't have a problem.... greenlee makes awesome tools
  3. Lou Braun

    Lou Braun Junior Member
    Messages: 7

    The Greenlee punch will easily handle any sheet metal on your F-250. The punch hole size might be too large though. I would try punching that size hole in a scrap piece of metal to make sure that you are satisfied with the larger hole.

    If clearance permits, a step drill does a decent job in drilling larger holes in sheet metal and may be easier than the punch.

    Lou Braun
  4. Hole Size

    The connector on the lamp is exactly 3/4" across. A 7/8" or .875 hole will allow 1/16" clearance on either side of the connector. The Greenlee 1/2" conduit punch will make a hole that is .89". That is only 15 thousandths of an inch wider than the 7/8" hole. I don't think that 15 thousandths will make much of a difference.