CurlyDave
Elite Member
Will that hole saw cut through 1/4" steel plate?
A hole saw is your best bet for cutting a 3/4" hole in 1/4" steel. If I were doing it in my shop, I would step up a notch in quality from the Kobalt hole saws shown and get a Bi-Metal Milwaukee, Blu-Mol, or even a Lenox. Use lots of cutting lube on the hole saw and a 1/2" drill with low RPMs. Use light feed pressure and see what happens.
If you have a grinder and want to increase your odds of success slightly, use a 1/4" drill to make the pilot hole and replace the drill in the center of the hole saw with a piece of 1/4" solid rod. You will need to grind a flat spot on it to simulate the flat spot in the pilot drill in the hole saw. This way you are not using the pilot drill as both a drill and a guide.