PILOON
Super Star Member
Hole saw works just fine BUT after the 1/4" pilot hole is drilled replace the bit with a plain 1/4" rod as otherwise the pilot hole will grow and you will end up with a very messy 4" hole with sharp jagged edges.
Need to cut a nice round 4" diameter hole in the end of steel barrels.
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medic0648
Gold Member
Plasma cutter or torch with a circle attachment works great also.
Yup, hole saw is an economical option that cuts a nicely shaped circle if, as noted above, one changes out the drill for the pilot hole with a plain rod once the metal is penetrated. However, also as noted it makes a major racket (use hearing protectors) and oil helps (so it's also messy). I recently made a "trailer septic" for my small travel trailer that spends the hunting season at a club (drum with 2 holes, one for inlet and other outlet to 4" peanut-expanded, wrapped drainage tubing). Yeah, I used thick plastic 55 gal drums, but the principle, and the hole saw, is the same.
Birdhunter1
Veteran Member
Lenox 4" hole saw on a heavy duty low speed drill works well. Like others have said keep it oiled. I have a 1 1/4" Lenox that you'd be hard pressed to tell it had cut anything but 1/4" paneling and I've probably used it for 50 holes in 1/4" mild steel.
CurlyDave
Elite Member
This is actually the way any good machinist will use a hole saw, and is in the directions for the higher quality saws.
To make it even easier, I recognized long ago that there is no need for the pilot hole to be drilled by a drill bit mounted in the center of the hole saw. I use a plain old 1/4" drill bit to drill the pilot hole and then switch to my hole saw which has a permanently mounted 1/4" solid rod in the center.
EddieWalker
Epic Contributor
I also recommend going with Lennox, which is sold at Lowes. I have a 4 inch that I use for light fixtures all the time, but we ruined it drilling 4 inch holes in Hardi siding. It's a miserable tool to work with because of how it randomly binds up and wants to twist the drill out of your hand. I have a half inch corded drill with a ton of power, but I'm afraid to use it for drilling with the hole saw because of the binding issues. I use my Makita cordless drill for this with the handle on it and even with that, it's still a battle.
If this is something you do all the time, that hole punch might be a worthwhile expense.
Eddie
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Plasma cutter would be so fast if you have access to one.
CurlyDave
Elite Member
The right tool for large hole saws is a Milwaukee HoleHawg. Not cheap, but I have never had anything try to rip the drill out of my hand.
Brad_Blazer
Veteran Member
Hydraulic Punch Driver w/ 5 Hydraulic Punches & Dies
You'll have to add the 4" punch.
You'll have to add the 4" punch.
SPIKER
Elite Member
I've had some Milwaukee's ripped out of my hands more than once, heck probably 50+ times... TOO much power most of the times, using big hole saws I prefer a 3/8" old B&D or Dewalt something with enough power but not enough to twist your wrist off your arms.
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