Cat flap in metal upvc door

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Hi all,

Really hoping someone will be able to help me out, I am trying to install a cat flap into a upvc door- something I though would have been quite straightforward!

I had a suspicion it would have metal inside as I think it is from around the 1970s , sure enough when I drilled the first hole (dewalt hammer drill) I felt it hit some kind of metal- I can't get through it at all having snapped a bit and pushed as hard as I can (borderline ruined the door). I drilled a larger hole in the middle of where the flap will go so I could have a look inside and there is what looks like metal with a shiny surface? It also seems to have broken as I can now hear it rattling Inside the door. Searching online people seem to think this should be easy to drill through but I cannot manage it.

Can anyone help?

Many thanks

Tom
 
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If it was a modern panel it would most likely be either 9mm of MDF or 3mm of aluminum. Im afraid I have no idea what they used in the 70's.

Can you take the panel out and look at it from the edge?
 
I think taking the panel out is a bit beyond me - is it possible to replace panels then? Do you know the approx cost for that?

Was using metal bits, tried a pilot with 3/4mm but they both snapped. Whatever it is it's a lot thicker than 3mm! Even if I could get through I'm not sure my jigsaw would be able to cut out the flap.
 
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Jigsaw would likely scratch up the thing, and they are hard to safely control vertical. If you can get a hole through the metal, you would be best with a reciprocating saw with a metal blade. Plenty of breaks for the blade to cool off though.
 

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