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Hole Saw?

JG Owens

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Apr 13, 2020
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Lehigh Valley, PA
I'm about to add some dust collection to my Unisaw and need suggestions on cutting a 4" hole through the steel for the dust port.
My original thought was to use a jig saw but the saw will remain in its upright position and that method would be awkward. I decided to go on Amazon and see what's offered in 4" hole saws. As you would imagine, they have them but I remain unconvinced this is the correct route.
Does anyone have experience using a large hole saw on steel? Thanks.
 
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Rc_Guy

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Doing fire sprinkler work we used plenty of these. We had to put sprinklers in an old safe once, we drilled 3 - 2" holes through 1" thick steel safe ceiling. We have also drilled through steel walls to run pipe through.

Start the hole with just the drill bit on, otherwise when the drill bit goes through the hole saw will catch and then bend or break the pilot bit.
 
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slowtwitch73

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Hellgate
You can do it, but it gets interesting at that size depending on what you are drilling with/through.. lots of cutting area.

Go slow.. if possible clamp a sacrifical backing to the work... wood or something. I did some 4" holes in stainless sheet and backed it with some Al scrap. With that much cutting area, things get hot fast even going slow.
 

cannuck

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Big holes in sheet metal work far better with a knockout punch if you have access or can rent. Greenlee seems to lead that pack (we use extensively at my main client, so I get to borrow them when needed).

 

dutchgray

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Should be pretty easy, use a drill with a safety clutch or be prepared for when it binds up, use cutting oil and run it slow and apply a decent amount of cutting force, with that many teeth in contact it's easy for them to just be rubbing and doing nothing but get hot.

I own a sheet metal nibbler so would probably use that in preference to a 4" hole saw.
 

Wrench97

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I used 4 1/8" hole saws to put the 4" round tail lights in the 3/16" steel rear panels on Semi trailers when we had to rebuild the rear door frame because of rust/rot. They work just lube it up and go slow.
 

John McA

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Pasadena
I'm about to add some dust collection to my Unisaw and need suggestions on cutting a 4" hole through the steel for the dust port.
My original thought was to use a jig saw but the saw will remain in its upright position and that method would be awkward. I decided to go on Amazon and see what's offered in 4" hole saws. As you would imagine, they have them but I remain unconvinced this is the correct route.
Does anyone have experience using a large hole saw on steel? Thanks.
Grind a nice square opening, and put a plate adapter. Make the square large enough to upgrade to 6 in dia. when you find out the 4 in didn't provide the volume.
Good luck,
John McA.
 

Sinatra

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Apr 22, 2013
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Does your Unisaw have a removable clean out door? You could either cutout the door for the dust connection or fabricate a plate out of metal or wood and cut a hole in that.
 
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timgunn1962

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Lancashire, England
A 4" holesaw can work well if you can run it slowly. As mentioned above, there is a risk of things going pear-shaped when the periphery makes contact. Things can also get wobbly as the pilot drill gets pushed around and shaves off the inside of the pilot hole. Expect to end up with an oversized hole with a pretty rough edge. Whenever possible, I use the holesaw to cut a hole through some scrap material (usually 1/2" MDF), clamp the scrap to the hole location, remove the pilot drill and cut the hole using the scrap as an external "pilot".

The first time I did this was because I needed a disk of stainless steel without a center hole. It worked so well that I've used the method whenever a fairly tidy holesawed hole is needed.

Some folk drill the 1/4" pilot hole and then use a piece of 1/4" drill rod as the pilot. I find this slightly better than just using the pilot drill, but not as good as the clamp-on-the predrilled scrap method.

The carbide-toothed holesaws, whether the SM-TCT range from Starret or the remarkably-similar-looking cheap ones from ebay or Amazon, are pretty good: I find I can get a much more accurately-sized hole with them and they cope with stainless steel better than the normal holesaws. However, they are intended for sheet metal so the depth of cut is very limited and there is usually a larger diameter ridge (safety stop collar) which means the 1/2" MDF is too thick. For these, I use thinner scrap. I've used them to 95mm (3 3/4") through 6mm (1/4") stainless steel in a drill press and to 2" through 1/16" steel with a cordless drill.

The Starrett CDT-TCT range has a 1" depth-of-cut and there are also very-similar-looking ones available elsewhere. The cheapies have performed fine for me , as have the Starrett ones, but I've not used any above about 32mm (1 1/4"). That was with a cordless drill.
 

John McA

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Hate to have to pick up or, tilt a Unisaw to do the above if it is stationed in place, in this shop. Especially if there is a back table and adjacent equip.
The access hole idea is good too. I assume Unisaw means a full metal cabinet w/o a moveable base. Right? Not sitting on pallets or not on a completely impenetrable floor?
 

Bert_

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I just drilled out the center in 4 steel Ford pickup rims with a 4 1/4" holesaw. I did start with a new holesaw but it's still nice and sharp. Used a big right angle drill, runs about 300 rpm. Went quick, less than a minute for each hole.
 

Rc_Guy

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I just drilled out the center in 4 steel Ford pickup rims with a 4 1/4" holesaw. I did start with a new holesaw but it's still nice and sharp. Used a big right angle drill, runs about 300 rpm. Went quick, less than a minute for each hole.
I’ve done all kinds of holes also, sounds like some guys are to nervous to drill big holes. Like I said above, I’ve drilled 2” holes through a 1” thick steel safe, with a battery drill.
 

tarbellb

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standard hole saw is fine, make sure your drill is up to the task, low gear, extra handle, and lube

a jig saw and nice metal blade will do the trick no problem too
 

Rc_Guy

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standard hole saw is fine, make sure your drill is up to the task, low gear, extra handle, and lube

a jig saw and nice metal blade will do the trick no problem too
I like high gear, low gear and if it catches could break my wrist, high gear I can stop the drill.
 

Mr_fixit

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Rustylvania
Big holes in sheet metal work far better with a knockout punch if you have access or can rent. Greenlee seems to lead that pack (we use extensively at my main client, so I get to borrow them when needed).

Aren't these really bigger than 4", more like 4.54" or larger, the size needed for a 4" sch40 electrical conduit fitting?
 

Death Row Dave

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Slow and steady wins the race . I always drill 3 equally spaced holes around near the edge of the hole to allow chips an escape route for large holes
 

cannuck

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Aren't these really bigger than 4", more like 4.54" or larger, the size needed for a 4" sch40 electrical conduit fitting?
I think Greelee sells punches and dies in both exact size and nominal pipe sizes. I only get to borrow electrical ones (i.e. conduit size = pipe size).
They also sell manual screw-type mandrels as well as the hydraulic ones.
Had a look. Their exact size punches go up in 1/16 increments in small sizes, then 1/8 and 1/4 as you go up....but they STOP at 3 3/4"
BUT: if you use a 3 1/2" conduit punch THAT is 4" OD.
 
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Monza Harry

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Dec 29, 2018
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Windsor ON
I have drilled some speaker holes in sheet metal inner car skins, by hand [corded 1/2" gear reduced drill motor] messy at best. The advise about the holes along the periphery works great (Death Row Dave) [I used 4 as that was easiest on a Bridgeport] I do like the idea from TimGunn1962 for the external pilot as well I have used the unthreaded part of a screw as a pilot as well. And the collective is right on with LUBE and Slow Motion, are your friends there. Harry
 
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