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#4604142 - 12/15/17 07:30 AM Hole Saw Drilling Tip
Traction Offline


Registered: 06/04/13
Posts: 978
Loc: iowa
After drilling many holes with a hole saw over the years, and messing up more than a few, a huge tip is to not use a drill bit in the hole saw. Especially on thin materials, or aluminum. Drill the pilot hole separately, and use a 1/4 drill rod, or cut the shank off of a long bit installed in the arbor to guide the saw. Otherwise if using a drill bit, your pilot hole keeps getting bigger, and the saw hole keeps getting bigger and uglier too. Yesterday I cut a 4 inch hole in the lower corner of my steel garage door for a dust collector port. Now I can connect up my 3/4 horse dust collector outside to pull welding fumes, dust, etc. right outside, plus I don't have to listen to it. There is a plastic blast gate attached on the outside of the door I got from Menard's for $5.




Edited by Traction (12/15/17 07:38 AM)
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#4604151 - 12/15/17 07:40 AM Re: Hole Saw Drilling Tip [Re: Traction]
Kira Offline


Registered: 08/19/10
Posts: 5208
Loc: Champlain/Hudson Valley
Grandpa raccoon can't fit through that! Wadda you, anti-family?

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#4604157 - 12/15/17 07:47 AM Re: Hole Saw Drilling Tip [Re: Kira]
Virtus_Probi Offline


Registered: 06/25/15
Posts: 3966
Loc: New England
Originally Posted By: Kira
Grandpa raccoon can't fit through that! Wadda you, anti-family?


Chipmunks, squirrels, and weasels will be A-OK!!!
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#4604158 - 12/15/17 07:48 AM Re: Hole Saw Drilling Tip [Re: Traction]
Langanobob Online   content


Registered: 04/24/09
Posts: 208
Loc: Reno, Nevada
That is an interesting tip and Iíll try it next time Iím cutting holes in thin material. Thanks!

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#4604170 - 12/15/17 08:01 AM Re: Hole Saw Drilling Tip [Re: Traction]
IndyIan Offline


Registered: 09/23/08
Posts: 9091
Loc: Ontario, Canada
Good idea! I've clamped a sacrificial piece of plywood to thin stuff to act as a guide as well. This way you can cut partial circles or bites.
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#4604429 - 12/15/17 12:05 PM Re: Hole Saw Drilling Tip [Re: IndyIan]
EdwardC Offline


Registered: 11/14/13
Posts: 1862
Loc: Chicago, IL
Originally Posted By: IndyIan
Good idea! I've clamped a sacrificial piece of plywood to thin stuff to act as a guide as well. This way you can cut partial circles or bites.


Which is also a great tip for when you need to re-drill for a larger hole!

I think the best hole saw tip I've used (particularly when drilling wood), is to drill a few holes around the edge of the hole to allow chips to fall.

https://www.familyhandyman.com/tools/saws/choose-the-right-hole-saw-for-your-project/view-all/

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#4605734 - 12/16/17 06:48 PM Re: Hole Saw Drilling Tip [Re: Traction]
another Todd Offline


Registered: 05/15/06
Posts: 2205
Loc: Lakeside CA
Originally Posted By: Traction
Yesterday I cut a 4 inch hole in the lower corner of my steel garage door for a dust collector port. Now I can connect up my 3/4 horse dust collector outside to pull welding fumes, dust, etc. right outside, plus I don't have to listen to it. There is a plastic blast gate attached on the outside of the door I got from Menard's for $5.


Good tip but why would you drill a through hole in a door that goes up and down. Sooner or later you are going to A) get sick of disconnecting hoses to open the door, or B) forget about it and open the door with hoses still attached and pull it apart, with possible damage.
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#4606016 - 12/17/17 08:12 AM Re: Hole Saw Drilling Tip [Re: another Todd]
Traction Offline


Registered: 06/04/13
Posts: 978
Loc: iowa
Originally Posted By: another Todd
Originally Posted By: Traction
Yesterday I cut a 4 inch hole in the lower corner of my steel garage door for a dust collector port. Now I can connect up my 3/4 horse dust collector outside to pull welding fumes, dust, etc. right outside, plus I don't have to listen to it. There is a plastic blast gate attached on the outside of the door I got from Menard's for $5.


Good tip but why would you drill a through hole in a door that goes up and down. Sooner or later you are going to A) get sick of disconnecting hoses to open the door, or B) forget about it and open the door with hoses still attached and pull it apart, with possible damage.

It's for occasional use, and the hoses just slip on. I'll use it for welding projects, or painting small parts inside during cold weather. I didn't want to go through the sidewall, but I could have. Other than that just remember to unhook if needing to open the door. I am more worried about opening the door with the rear hatch of my Tahoe open.


Edited by Traction (12/17/17 08:19 AM)
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#4606053 - 12/17/17 08:59 AM Re: Hole Saw Drilling Tip [Re: Traction]
SHOZ Offline


Registered: 06/28/03
Posts: 5744
Loc: Illinois
I cut a hole where there should have been a factory subframe bushing for the rear of my Genesis Coupe last summer. Installed a factory bushing. The subframe was stamped steel and quite hard. There was already somewhat of a hole there. But I used the plywood backer board and also figured out to get rid of the bit and used a cut off bolt for the guide.

The hole saw wandered a bit but the OE hole was in a recessed area and that kind of contained the run out. It turned out good as it also thinned the steel and in the end pushed it out to for some sort of a flange.


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#4606730 - 12/17/17 09:43 PM Re: Hole Saw Drilling Tip [Re: Traction]
eljefino Offline


Registered: 06/15/03
Posts: 32631
Loc: ME
^ That's cool but did Hyundai just forget that step? Hole guy called in sick? LOL

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#4606939 - 12/18/17 06:52 AM Re: Hole Saw Drilling Tip [Re: eljefino]
SHOZ Offline


Registered: 06/28/03
Posts: 5744
Loc: Illinois
Originally Posted By: eljefino
^ That's cool but did Hyundai just forget that step? Hole guy called in sick? LOL
It's speculated that the motor mounts are so squishy and allow so much movement they had to just use three bushings to hold the rear subframe in it could move with the motor. It sure made a major difference in planting the rear end when cornering.
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#4607617 - 12/18/17 07:19 PM Re: Hole Saw Drilling Tip [Re: SHOZ]
HangFire Offline


Registered: 08/21/13
Posts: 2506
Loc: Central Maryland
Originally Posted By: SHOZ
[It's speculated that the motor mounts are so squishy and allow so much movement they had to just use three bushings to hold the rear subframe in it could move with the motor.

Read 3 times, still can't parse this.
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