Welcome to the North American Subaru Impreza Owners Club Thursday March 28, 2024
Home Forums Images WikiNASIOC Products Store Modifications Upgrade Garage
NASIOC
Go Back   NASIOC > NASIOC Technical > Custom Fabrication, Welding & Tools

Welcome to NASIOC - The world's largest online community for Subaru enthusiasts!
Welcome to the NASIOC.com Subaru forum.

You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, free of charge, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join our community today!

If you have any problems with the registration process or your account login, please contact us.







* As an Amazon Associate I earn from qualifying purchases. 
* Registered users of the site do not see these ads. 
Reply
 
Thread Tools Display Modes
Old 01-16-2013, 08:18 PM   #1
bmw325ix
Scooby Newbie
 
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
Default Hole saw brands?

Simple question, The hard ware store brand hole saws I have and driving me nuts. Say I use a 2.5" saw to punch a hole, that hole ends up leaving about an 1/8th inch gap all the way around a 2.5" pipe.

This example came about when I made intercooler end tanks. So does anyone know a brand that is a more exact size. Maybe a brand that measure by the OD.
* Registered users of the site do not see these ads.
bmw325ix is offline   Reply With Quote
Sponsored Links
* Registered users of the site do not see these ads.
Old 01-16-2013, 10:22 PM   #2
bugeyesubie
Scooby Specialist
 
Member#: 179783
Join Date: May 2008
Chapter/Region: W. Canada
Location: Calgary
Vehicle:
2002 WRX
Silver STi swap 380wph!!

Default

could you use a 2 1/4" hole saw then? maybe just sand out the rest for a perfect fit? could maybe find a 2 5/16" possibly
bugeyesubie is offline   Reply With Quote
Old 01-16-2013, 10:34 PM   #3
bmw325ix
Scooby Newbie
 
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
Default

Yeah that's an option I've though about but don't want to buy one and hope for best. They get exspensive.
bmw325ix is offline   Reply With Quote
Old 01-17-2013, 01:34 AM   #4
Zefy
Scooby Specialist
 
Member#: 105104
Join Date: Jan 2006
Chapter/Region: VIC
Location: Coquitlam, BC, Canada
Vehicle:
1979 BRAT / 01 RSTI
99 2.5TS (DEAD)

Default

are you using a hand drill when cutting or are you using a drill press? Drill presses tend to hold the saw a little better and cause it to walk less because it is less reliant on the centre drill to keep it aligned.

If you are using a drill press or mill, you can move up to using something like a trepanning cutter(annular cutter) or a fly cutter. But if you're worried about the price of a hole saw though these are probably not for you...

Probably the easiest is what bugeyesubie said... under-size, then trim to fit.

EDIT: Also the locking mechanisms for holding the hole saw in the arbour with the two little pins tend to be quite loose. You can try and bottom out the hole saw (making it really tight on the threads) to keep it from moving around. Put a washer on first though so you still have a chance to get the hole saw off the arbour when you're done.
Zefy is offline   Reply With Quote
Old 01-17-2013, 10:29 AM   #5
bmw325ix
Scooby Newbie
 
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
Default

I try to use the drill press as much as possible. There certainly is a difference when I use the hand drill. Annular cutter looks interesting, I dont mind spending money on tools generally but Ive just had bad luck with hole saws so continuing on that road seems a waste.

If new tool will make a better cut its worth the cost to me. I think Im going to take a caliper over to the hardware store and see if I can measure a some different brands.

Last edited by bmw325ix; 01-17-2013 at 10:35 AM.
bmw325ix is offline   Reply With Quote
Old 01-19-2013, 05:19 PM   #6
Surb00
Scooby Newbie
 
Member#: 27132
Join Date: Oct 2002
Location: Colorado Springs, Colorado
Vehicle:
1999 2.5 RS-T
Rally Blue

Default

All brands measure by the o.d. I think your problem is likely more from the saw walking and the pilot bit not being squared with the saw. The hole saw itself is going to be very close to the indicated diameter. A quality mandrel is very important and Lennox brand bi-metal saws work perfect for me. Another option is a Rotabroach, they're good for tougher and or thicker material.
Surb00 is offline   Reply With Quote
Old 01-19-2013, 06:58 PM   #7
bmw325ix
Scooby Newbie
 
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
Default

^^^ Im beginning to agree the more things I take the time to measure. I know I have had some less then quality arbors in the past but I usually bin them as soon as I notice.
bmw325ix is offline   Reply With Quote
Old 01-26-2013, 03:21 PM   #8
Mr. Wagon
Scooby Newbie
 
Member#: 244383
Join Date: Apr 2010
Default

Quote:
Originally Posted by Zefy View Post

If you are using a drill press or mill, you can move up to using something like a trepanning cutter(annular cutter) or a fly cutter. But if you're worried about the price of a hole saw though these are probably not for you...

EDIT: Also the locking mechanisms for holding the hole saw in the arbour with the two little pins tend to be quite loose. You can try and bottom out the hole saw (making it really tight on the threads) to keep it from moving around. Put a washer on first though so you still have a chance to get the hole saw off the arbour when you're done.

Annular cutters are best if you can afford it. At work well put them through 100+ inches of material before they need to be resharpened.

A washer pack out works well and if you're in a pinch layers of masking tape will work all the same.

As with any cutting operation, its all about proper speed and lubrication.
Mr. Wagon is offline   Reply With Quote
Old 02-15-2013, 09:50 PM   #9
mikemcl
Scooby Newbie
 
Member#: 346961
Join Date: Feb 2013
Location: rockledge FL
Vehicle:
2006 wrx
wrb

Default

Some hole saws use offset teeth to create space for the cutter as it penetrates.these offset teeth are splayed out, one inside one outside to open up the kerf in cuts through wood mostly. If you take the 2.5 holesaw to the grinder and knock off the splayed out teeth, it will be closer to the dimension you are looking for.
mikemcl is offline   Reply With Quote
Old 02-17-2013, 12:04 PM   #10
Dirtracr95
Scooby Newbie
 
Member#: 346599
Join Date: Feb 2013
Chapter/Region: MWSOC
Location: Des Plaines, IL
Vehicle:
2003 WRX
WRB

Default

It is mainly due to the walk in the arbor and possibly your drill. My snap-on 1/2" pneumatic drill's shaft is bent because well its fallen off the trucks ive built/worked on too many times. If there is any wobble or walking when cutting you might not be holding your drill too tight assuming its a hand drill. If you loosen your grip and let the drill do the wobbling instead of the holesaw your hole should turn out better.
+1 on the splayed tooth comment. The Banco holesaws I use at work have splayed teeth and will generally overcut. Ive used from 3/4" to 6" holesaws and this holds true for all of them from what ive seen.

If your looking for a perfect fit I would say either use the next size smaller and enlarge or plasma the hole using that tool for making circles and file the edges.
Dirtracr95 is offline   Reply With Quote
Old 03-05-2013, 06:41 AM   #11
bmw325ix
Scooby Newbie
 
Member#: 204652
Join Date: Mar 2009
Location: newburyport, ma
Default

Quote:
Originally Posted by mikemcl View Post
Some hole saws use offset teeth to create space for the cutter as it penetrates.these offset teeth are splayed out, one inside one outside to open up the kerf in cuts through wood mostly. If you take the 2.5 holesaw to the grinder and knock off the splayed out teeth, it will be closer to the dimension you are looking for.
Gave this a shot last night, works like a dream. thanks for the tip
bmw325ix is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

All times are GMT -4. The time now is 03:07 PM.


Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2024, Jelsoft Enterprises Ltd.
Powered by Searchlight © 2024 Axivo Inc.
Copyright ©1999 - 2019, North American Subaru Impreza Owners Club, Inc.

As an Amazon Associate I earn from qualifying purchases.

When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission
Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.