Hole saws are used on aluminum every day in industry...for custom work.
For the few holes you're cutting, you won't need any lubricant. Just
make sure your pilot bit is in tight, the set screws tend to rattle
loose. Good luck.

John Smith wrote:
Hi Folks,
I am now at the stage of needing to install the dashboard instruments on my
boat rebuild. I have a choice of buying a custom panel or making one myself
which is the preferred choice. I have a piece of 4mm aluminium sheet which I
would like to use. Can anyone advise me on cutting circular holes in the
stuff. I have a 'Hole saw' set which describes its self as 'Bi-metal' It
works fine in wood and plastic. has anyone tried them on aluminium please?
Most of the holes will be for 2" instruments although there is a larger
Tacho which is approx 3.5 inches. any suggestions will be appreciated even
if they are of 'The don't even think about it' variety.
many thanks
Peter