How to Properly Use a Hole Saw (page 2 of 2)

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Start Slowly and Hold on Tight

When you need a clean, splinter-free hole, drill in from both sides. The key to getting a perfectly straight hole is to ensure even contact at the start. That will put your drill at a right angle to the door.

Tip:Most locks and door latch sets require a 2-1/8 in. hole, so if you buy aset of hole saws, make sure it contains this size.

Buying Hole Saws
For as little as $15, you can buy a set of carbon-steel hole saws for drilling wood. For about $45, you can buy a set of bimetal hole saws that will cut wood and metal and last a lot longer. You can also buy specialty hole saws coated with Carborundum or diamond grit to cut hard materials like tile and stone. These saws, however, won’t cut wood.

Most hole saws mount to a separate centering guide called an arbor. Others are one piece. Better arbors (about $12) have two pins that slide into holes in the bottom of the hole saw to lock the saw in place. Match the arbor to your saw and check that it will fit in your drill. Some arbors require a 1/2-in. chuck and drill.

Enlarge Existing Holes
There’s just one problem when you need to enlarge an existing hole. The center bit on your hole saw must be engaged in wood before you can start a hole; otherwise, the saw will just spin and gnaw its way across the surface, leaving a mess behind. Clamping a 1/4-in. piece of plywood over the existing hole is the easiest solution. Another method is to jam a wood plug into the existing hole.

Chisel Out the Core for Deep Holes
You can drill deep holes with a hole saw if you chisel out the wood plug as you go. This is useful when you only have access to one side of thick material and your hole saw isn’t long enough to go all the way through. If you don’t have a chisel handy, break out the plug with a standard screwdriver.

Hole Saws Are Surprisingly Hazardous
Tilting the drill or hitting a nail with the hole saw while you’re drilling can cause the saw to bind and the drill motor to twist violently in your hands. The powerful torque can slam the drill into your face or strain your wrist. Since binding is hard to predict, your best defense is to brace the drill handle against your hip or leg if possible and maintain a firm, two-handed grip. If your drill has a side handle, use it. In addition, take the following precautions for safe hole cutting.

Keep the drill going straight to avoid binding the hole saw.
Don’t wear loose clothing or jewelry that could become entangled in the hole saw.
Locate the trigger speed lock-on button (if your drill has one) and avoid pressing it as you’re drilling. (I like to disable these locks by filing or sawing off the button so it’s flush to the handle.)