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Hole Saw Drilling Tip #4604142
12/15/17 08:30 AM
12/15/17 08:30 AM
Joined: Jun 2013
Posts: 1,036
iowa
Traction Offline OP
Traction  Offline OP
Joined: Jun 2013
Posts: 1,036
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.



Last edited by Traction; 12/15/17 08:38 AM.

Certified Tire Service Instructor since 2009
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Re: Hole Saw Drilling Tip [Re: Traction] #4604151
12/15/17 08:40 AM
12/15/17 08:40 AM
Joined: Aug 2010
Posts: 5,668
Champlain/Hudson Valley
Kira Offline
Kira  Offline
Joined: Aug 2010
Posts: 5,668
Champlain/Hudson Valley
Grandpa raccoon can't fit through that! Wadda you, anti-family?

Re: Hole Saw Drilling Tip [Re: Kira] #4604157
12/15/17 08:47 AM
12/15/17 08:47 AM
Joined: Jun 2015
Posts: 4,225
New England
Virtus_Probi Offline
Virtus_Probi  Offline
Joined: Jun 2015
Posts: 4,225
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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Re: Hole Saw Drilling Tip [Re: Traction] #4604158
12/15/17 08:48 AM
12/15/17 08:48 AM
Joined: Apr 2009
Posts: 222
Reno, Nevada
Langanobob Offline
Langanobob  Offline
Joined: Apr 2009
Posts: 222
Reno, Nevada
That is an interesting tip and Iíll try it next time Iím cutting holes in thin material. Thanks!

Re: Hole Saw Drilling Tip [Re: Traction] #4604170
12/15/17 09:01 AM
12/15/17 09:01 AM
Joined: Sep 2008
Posts: 9,192
Ontario, Canada
IndyIan Offline
IndyIan  Offline
Joined: Sep 2008
Posts: 9,192
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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Re: Hole Saw Drilling Tip [Re: IndyIan] #4604429
12/15/17 01:05 PM
12/15/17 01:05 PM
Joined: Nov 2013
Posts: 1,916
Chicago, IL
EdwardC Offline
EdwardC  Offline
Joined: Nov 2013
Posts: 1,916
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/

Re: Hole Saw Drilling Tip [Re: Traction] #4605734
12/16/17 07:48 PM
12/16/17 07:48 PM
Joined: May 2006
Posts: 2,206
Lakeside CA
another Todd Offline
another Todd  Offline
Joined: May 2006
Posts: 2,206
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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Re: Hole Saw Drilling Tip [Re: another Todd] #4606016
12/17/17 09:12 AM
12/17/17 09:12 AM
Joined: Jun 2013
Posts: 1,036
iowa
Traction Offline OP
Traction  Offline OP
Joined: Jun 2013
Posts: 1,036
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.

Last edited by Traction; 12/17/17 09:19 AM.

Certified Tire Service Instructor since 2009
50 Chevy Fire Truck
13 Tahoe Pursuit
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Re: Hole Saw Drilling Tip [Re: Traction] #4606053
12/17/17 09:59 AM
12/17/17 09:59 AM
Joined: Jun 2003
Posts: 5,921
Illinois
SHOZ Offline
SHOZ  Offline
Joined: Jun 2003
Posts: 5,921
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.




2008 Hyundai Accent 1.6L 5 sp manual hatchback
2010 Hyundai Genesis Coupe Track 2L Turbo 6sp manual
Re: Hole Saw Drilling Tip [Re: Traction] #4606730
12/17/17 10:43 PM
12/17/17 10:43 PM
Joined: Jun 2003
Posts: 33,091
ME
eljefino Offline
eljefino  Offline
Joined: Jun 2003
Posts: 33,091
ME
^ That's cool but did Hyundai just forget that step? Hole guy called in sick? LOL

Re: Hole Saw Drilling Tip [Re: eljefino] #4606939
12/18/17 07:52 AM
12/18/17 07:52 AM
Joined: Jun 2003
Posts: 5,921
Illinois
SHOZ Offline
SHOZ  Offline
Joined: Jun 2003
Posts: 5,921
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.


2008 Hyundai Accent 1.6L 5 sp manual hatchback
2010 Hyundai Genesis Coupe Track 2L Turbo 6sp manual
Re: Hole Saw Drilling Tip [Re: SHOZ] #4607617
12/18/17 08:19 PM
12/18/17 08:19 PM
Joined: Aug 2013
Posts: 2,531
Central Maryland
HangFire Offline
HangFire  Offline
Joined: Aug 2013
Posts: 2,531
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.


Various musings: http://hangfire.net

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