mrcaptainbob
Platinum Member
I'd sure go the hole saw route. Especially since there's a good chance of needing it again......by the way....use a good quality cutting oil......
If you are in need of GOOD quality drill bits, try DrillBitWarehouse.com
They manufacture as well as distribute High speed, cobalt and solid carbide drill, reamers and all kinds of great stuff.
Drill Bit Warehouse: Quality Drill Bits For Less!
I have had great success using holesaws, and a drill press. Accurately mark and center-punch the hole-clamp the piece TIGHTLY to the drill press table (I use a block of wood under my holes to save the drill table and bit)-and drill SLOWLY; use plenty of cutting oil, this will keep from overheating the bit, and also give greater accuracy. Trying to rush tends to bend the pilot off center, or cause the holesaw to cut crooked. I have used holesaws up to about 2-1/2" with very good accuracy. I will sometimes, as others have suggested, drill halfway through a thick workpiece, then flip it over and drill the other side. That is, til I get the mill...
Dan