That is thick plastic. My 2 cents ... Jigsaw Lots of drill holes drilled close together in a circle. Drill a large hole for a hacksw blade then re-assemble blade into hacksaw while located in hole drilled in cap. Fret saw similar to above. borrow a hydraulic hole punch, these are great fun Sharpen a socket with angle grinder/bench grinder then use as a punch with the aid of a vice and a larger socket. I have often used the vice with home made punches to press thru thick material. Have often used stanley blades to cleanly knife thru thick material with the aid of a vice. Chisel and hammer. Might fracture the plastic. > > What I need to do is knock a ~45mm hole in the front of one of the pipe > caps. > > Problem 1: these are EXTREMELY thick pipe caps. The plastic walls are > about 15mm thick! --=20 http://www.piclist.com PIC/SX FAQ & list archive View/change your membership options at http://mailman.mit.edu/mailman/listinfo/piclist .