Ideas...How To Widen Console Thru Hole

[boatnamesue]

Pictured below is my fiber console, and inside the red circle you'll see a hole.  I use this hole to slip thru the pole of a big umbrella.  The pole then inserts into larger diameter pvc pipe, which is cemented in a 1 gallon low profile bucket.  The umbrella I was using is no more, so I went out and bought a new one...a better one actually, more coverage and more durable.  The outer diameter of this new umbrella pole is 1.5".  The existing hole you see in the picture is 1" diameter.  So I need to widen the diameter by minimum 1/2", at which point I can hand sand off a few millimeters so the new pole will slide through yet be snug.  Problem is, if I choose to use a 1.5" spade drill bit the center tip will not have a surface to spin on axis.  If you've ever tried using a spade to widen a hole you'll know what I'm talking about.  It's tough to get a clean cut.  I thought of using a jig saw but the steering wheel would be obstructing, plus there's only like 2" of flat surface to work with.  A drimel saw could work, but do I really want to go drop the dough in order to cut a 1.5" circle...I prefer not to.  So, anyone have any ideas?? 

[theFunsmith]

If you can wedge a piece of wood in there from the back side of the hole, you can center drill the wood and run a proper size hole saw.

[mshugg]

If you can wedge a piece of wood in there from the back side of the hole, you can center drill the wood and run a proper size hole saw.

You can do this, or you can screw a small block behind the hole for a center.  Another option is to instal 2 hole saws on the same arbor.  The first is the same size as the hole and acts as the pilot for the second hole saw.

[boatnamesue]

Appreciate the responses guys.  I'm gonna go the route of using a piece of wood on the backside.  I have to make 2 small thru holes outside the diameter of the hole anyway, so I figured to drill out these 2 holes and then drill same 2 holes through wood, lock wood in place with the bolts I've already got.  That way the wood won't move when I start drilling.  We'll see how it goes.

[GoneFission]

Do you know someone who is an ironworker?  They use reamers that go from 3/4" to 1 1/2" - that would work fine for your need - kinda like a big step drill. 

[love2fish]

2 recommendations:

1. harbor freight: hole saw kit- you can "stack" the 1 inch inside the 1.5" and use a washer or 2 as a spacer- this will allow you to insert the 1 inch as a guide and get a MUCH cleaner cut for the desired size.

2. on a 3/4" or larger piece of wood- drill your desired hole size. clamp this to the top of your console and use it as a guide for the new hole.

[boatnamesue]

Used a thin piece of wood under hole.  Broke through it on first go around.  Doubled the wood.  Worked second go around.