Drilling round holes

[edekoning]

I need to make several holes in my cabinet with varying diameters (4.5 cm - 15 cm). What are my options for making such holes? I know there are spade and frostner drill bits, but these are only for small diameters. At a local shop I saw several hole-saws, but non were the correct diameter. So any suggestions?

[Drnick]

Rather then drilling can you not cut out the circle with a jigsaw and then finish with a router.  Or use a large drill bit to make holes around the inner edge of circle and then router/sandpaper to clean up).

Finally how about one of these? It will do anything from 30mm to 260mm  (But it isn't cheap)

http://www.tool-wise.com/product_catalogue/tool_wise_adjustable_hole_saw/index.html

[edekoning]

Yes I could just use a jigsaw+router+sanding, but I was hoping for some solution that did not require freehanding. But then again, might as well try it to see if the result are acceptable.


Jeez, that adjustable hole saw sure is cool, but way too expensive.

[MadMagpie]

check out this page

http://www.ukworkshop.co.uk/forums/viewtopic.php?t=4406

[yaksplat]

The $23 Solution

http://www.amazon.com/General-Tools-55-Circle-Cutter/dp/B00004T7P1/ref=sr_1_1?ie=UTF8&qid=1342094442&sr=8-1&keywords=fly+cutter

This works like a champ, as long as you have a drill press.

[Mysterioii]

Dremel makes little circle cutter attachments...  I have a big "accessory kit" of various bits and cutoff wheels that actually came with one of these but I've never used it.  But, they exist, and only 12 bucks.  I imagine you'd have to be pretty careful to make sure your center pin doesn't walk and ruin your cut...

http://www.amazon.com/Dremel-678-01-Circle-Cutter-Straight/dp/B000HI5WTY/ref=sr_1_1?s=hi&ie=UTF8&qid=1342094859&sr=1-1&keywords=dremel+hole+cutter

[kahlid74]

I use the Rotozip with this attachment to drill holes up to 4" in diameter - http://www.amazon.com/RotoZip-CRCT1-Circle-Cutting-Attachment/dp/B0000224P1/

[Woodshop Flunky]

Not the cheapest solutions, but this jig makes perfect circles... and is dirt simple to use.

http://www.amazon.com/Jasper-200J-Circle-Cutting-Plunge/dp/B00009K77A/ref=sr_1_1?s=hi&ie=UTF8&qid=1342114925&sr=1-1&keywords=Circle+cutting+jig

[Franco B]

I make a template from ~3mm/ 1/8" acrylic using a adjustable circle cutter like [this]

I then use that with a flush trim bit to route the material.

The acrylic cuts easily as it's a thin piece and it's also hard wearing and ideal for running a bearing along. I don't really like using MDF for templates as it's too soft and the bearing can dig into the template giving you an incorrect profile which can be an issue if accuracy or repeatability is key.

As the template material is thin I sometimes need to stick spacer pieces of acryic to the template to increase the height between the material to be cut and the template. This is to ensure the end of the flute clears the top of the material.

[edekoning]

Thanks for all the suggestions!

I'll be making something similar to what MadMagpie suggested. I wanted to that this weekend, but got sick As I'm also going on vacation in a few days, it will take some time before I can post any results.