How can I cut a hole in a lid of a tin can so it's smooth? (see attachment)

Not looking to take whole lid off, like with a can opener. Want to leave some of lid on can.

It won't have to pass close inspection but want it smooth enough to not stand out from a distance (there will be an insert in the hole)

I've tried using my dremel tool but no matter what attachments I use it causes dents or leaves ragged edges. Might a jewelry saw work? I've seen them online, but never used one.

Any suggestions would be appreaciated.

Click here to view attached image.

A jewelry saw could work, yes. You'd want one of the wire types, and you'd have to start off by drilling a hole in the lid so that you can thread the saw wire in before attaching it to the bow of the saw.

However, that also means you need the other end of the can to be open, but I guess it probably is?

You could try using the dremel to make a rough hole of a smaller diameter than your desired finished size. Then use a half round metal file to clean up the edges. Or, have you tried a grinding stone tone on the dremel? Something like this: https://www.amazon.com/Dremel-952-Alumin......IW&psc=1

Hello Imgic(!),
...you got me thinking. 🤔

I'll admitt, right away:
"I HAVEN'T the answer."
..but.. 😊

I,.....wouldn't 'jewelry saw' it.
The pushing and pulling,..,would warp the can top.

'Dremel' it?
Obviously not.

I would 'punch' it.

From the 'outside' in.
A wooden block on the inside.
firmly supporting the can...completely.

For a 'punch'..? 🤔
THAT'S THE $1,000,000.00 question.

I would find a pipe,
with an outer-diameter,
of the hole I wanted.
With a file,....or Dremel,..sharpen the INNER(!) edge,
of the pipe.
Then,....with ONE clean hit(!..!).
"pOp!.
(From the outside,.,,inward.)

'bAm!'
....one clean pop.
,...one clean hole!
,,.,,with luck. 🙃

All the best,
gallagher

p.s.: Sorry,,,
but,...
watcha making? ☺️
Thanks.

Thanks all. We’re getting ready to move back to Midwest, so will put project on hold for a bit. I’ll try saw, but also intrigued by trying a punch. Will play around with it.

I’m trying to make a gimmicked can for a cups and balls variation. I hve the routine in my head…just need to see if it’s physically practical.

If you have a drill press and the can is strong enough to clamp tightly, a hole saw might work to cut a nice round hole. You'll still want to smooth the edge to remove any burrs but I think the result should be pretty smooth to begin with.

Take it to a small, independant machine shop and get it cut on a laithe. Cheaper than getting your finger reattached
and they'll get it perfictly centered, and do it right the first time.

Thanks. I’ve neighbor who’s a machinist with Boeing. He’s got pretty decent home shop. I’ll ask him about lathe.

If you remove the bottom neatly with a can opener, then punch through the can and outward, whatever method you use to make the hole, you'll be left with an easier cleanup with the mess facing outward, then just glue the bottom back on.

Without a press, I bet using a pipe like the other person said would work just fine.

Buy a hole punch set online. Then punch it. It will be a little bent around the hole. Tap this back with a rubber hammer. Then lightly file the hole edges or use a dremel.
Perfect hole. I have made karate coins with this.