• Use the proper arbor recommended for the particular hole saw being used.
  • The drill must extend approximately 1/16" beyond the tips of the teeth.
  • Make sure the material being cut is held securely, to prevent turning or vibrating.
  • The hole saw must be square or flush with the workpiece when starting to cut. Slow, steady feed pressure should be applied.
  • To clear chips efficiently, the hole saw can be worked in and then out for chip relief.
  • Use a good cutting oil for lubrication and to help clear the chips. Cut cast iron dry.
  • Check drive pins on occasion to be sure vibrations have not disengaged the pins from pin holes.
RECOMMENDED OPERATING SPEEDS FOR BI-METAL HOLE SAWS
SIZE SIZE LENGTH MILD STEEL TOOL STEEL & STAINLESS CAST IRON BRASS ALUMINUM WOOD
INCH MM FEET RPM RPM RPM RPM RPM RPM
9/16 14 0.147 580 300 400 790 900 3000
5/8 16 0.164 550 275 365 730 825 3000
11/16 17 0.180 500 250 330 665 750 3000
3/4 19 0.196 460 230 300 600 690 3000
13/16 21 0.213 425 210 290 580 660 3000
7/8 22 0.229 390 195 260 520 585 3000
1 25 0.262 350 175 235 470 525 2700
1 1/16 27 0.278 325 160 215 435 480 2700
1 1/8 29 0.295 300 150 200 400 450 2700
1 3/16 30 0.311 285 145 190 380 425 2400
1 1/4 32 0.327 275 140 180 360 410 2400
1 5/16 33 0.344 260 135 175 345 390 2400
1 3/8 35 0.360 250 125 165 330 375 2400
1 7/16 37 0.376 240 120 160 315 360 2400
1 1/2 38 0.393 230 115 150 300 345 2400
1 9/16 40 0.409 220 110 145 290 330 2100
1 5/8 41 0.425 210 105 140 280 315 2100
1 11/16 43 0.442 205 100 135 270 305 2100
1 3/4 44 0.458 195 95 130 260 295 2100
1 13/16 46 0.475 190 95 125 250 285 2100
1 7/8 48 0.491 180 90 120 240 275 2100
2 51 0.524 170 85 115 230 255 2000
2 1/16 52 0.540 165 80 110 220 245 2000
2 1/8 54 0.556 160 80 105 210 240 2000
2 1/4 57 0.589 150 75 100 200 225 2000
2 5/16 59 0.605 145 75 95 195 225 2000
2 3/8 60 0.622 140 70 90 190 220 2000
2 1/2 64 0.655 135 65 85 180 205 1850
2 9/16 65 0.671 130 65 85 175 200 1850
2 5/8 67 0.687 130 65 85 170 195 1800
2 11/16 68 0.704 130 65 80 170 190 1800
2 3/4 70 0.720 125 60 80 160 185 1800
2 7/8 73 0.753 120 60 75 160 180 1800
3 76 0.785 115 55 70 150 170 1800
3 1/8 79 0.818 110 55 70 140 165 1500
3 1/4 83 0.851 105 50 65 140 155 1500
3 3/8 86 0.884 100 50 65 130 150 1500
3 1/2 89 0.916 95 45 60 130 145 1200
3 5/8 92 0.949 90 45 60 120 140 1200
3 3/4 95 0.982 90 45 60 120 135 1200
3 7/8 98 1.014 90 45 60 120 135 1200
4 102 1.047 85 40 55 110 130 1000
4 1/8 105 1.080 80 40 55 110 120 1000
4 1/4 108 1.113 80 40 55 110 120 900
4 3/8 111 1.145 80 40 50 100 120 900
4 1/2 114 1.178 75 35 50 100 105 900
4 3/4 121 1.244 75 35 50 92 95 900
5 127 1.309 65 30 45 90 90 800
5 1/2 140 1.440 60 25 40 85 85 800
5 3/4 146 1.505 55 25 35 75 75 800
6 152 1.571 55 25 35 75 75 800

Problem Solving

Trouble removing jammed slugs

  • Use an orbiting motion with the drill motor when feeding the hole saw into the material, but keep the orbiting motion within the size of the hole being cut, to avoid creating an oversized hole.

Trouble cutting thick material

  • Enter and exit the cut frequently to clear chips.
  • Drill chip-clearing holes around the perimeter of the cut.