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Hole Saw - experience - help please.
Richardgregory:
Thank you! I'll try it in my next practice run.
--- Quote from: tron319 on March 05, 2021, 05:21:55 am ---I needed to the do the same thing (3 1/4" hole) for a trackball. I went with a forstner bit instead of a hole saw. Found a decent not expensive one that worked perfectly on multiple panels. Technique:
- Center punch the center of the hole (just a small mark to know where the tip goes)
- I used a drill press set to low speed and a backing board
- Drill into the panel until part of the hole is cut - say 1/8" into the wood
- Then I removed and cut out a hole about 3" with a hole saw. The reason is to get rid of a bunch of the material from the center. The rough edge of the hole saw is no problem as I'll finish with the smooth the forstner bit
- Put the panel back on the drill press, align the forstner bit to the groove you already cut and finish it right through
The last step is very easy as a bunch of the material was removed with the hole saw.
I did the forstner cut on a drill press but you could do both with a hand drill ensuring you keep it vertical/level.
Hope that helps!
--- End quote ---
PL1:
Another option is a Dremel or router with a circle-cutting jig.
Scott
Zebidee:
When using a hole-saw, it always helps to pre-drill the centre guide hole to same size as arbor (that's the drill bit in the middle). That helps keep your work central so you can focus on cutting the outer circle. The arbor shouldn't be doing any cutting work at all, just guiding the hole saw into the cut.
Richardgregory:
Thanks! I didn't know such existed. I have a dremel tool, so I could try this as well, but I'm not sure how great it will be on 3/4" plywood.
--- Quote from: PL1 on March 05, 2021, 01:06:45 pm ---Another option is a Dremel or router with a circle-cutting jig.
Scott
--- End quote ---
PL1:
--- Quote from: Richardgregory on March 06, 2021, 11:39:52 am ---Thanks! I didn't know such existed. I have a dremel tool, so I could try this as well, but I'm not sure how great it will be on 3/4" plywood.
--- End quote ---
If you try to do it in a single pass, it won't be very good. :lol
- Multiple shallow passes are the way to go.
- Drill the pivot hole all the way through.
- Cut most of the way through on one side -- preferrably the top.
- Insert 3 or 4 dowels/wedges in the cut to hold the center plug in place or use double-sided tape to fasten the center plug to a board and clamp the control panel to the board. Either way, you don't want the center plug to shift when you finish the cut or the Dremel might take a bite out of the otherwise perfect hole.
- Finish cutting through from the other side. (reduces splintering/blowout)
Scott
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