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.
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