Hole Saw-9 Tips on Customizing Hole Saw to your Size

It’s challenging to use a hole saw to expand a premade hole in a wall or through a piece of material. After cutting, you’d realize the arbor or pilot drill bit wouldn’t have a grip anymore. So an attempt to cut a bigger one would be arduous.

You’d need a custom Hole saw when you need to make unique holes in a specific dimension. But it is difficult expanding the Hole saw itself. So, when you need to create a Hole, but your Hole saw doesn’t match what you need, what do you do? Here are nine tips you need to know when you’re considering customizing your Hole saw to your size.

Builder worker cutting electrical chase in concrete wall with circulation saw drill diamond crown

(Builder worker cutting electrical chase in concrete wall with circulation saw drill diamond crown.)

1.What is Hole Saw?

A hole saw is a kind of drill bit with a different working mechanism and application. A hole saw specifically makes holes without having to cut up the core material. It has a cylindrical cup with a serrated edge. Its design is such a way that it has a saw blade and a pilot drill bit or arbor. When turned on, the saw teeth cut the piece of material while the arbor forms an anchor at the center.

A hole saw has two different types of steel joined, forming the edge of the cutting part of the saw. There is high-speed steel, and the soft spring joined together, which creates a durable edge. A hole saw comes in different sizes for cutting different diameters of holes. Manufacturers also use different types of materials to make a hole saw. Depending on what you need a hole saw for, but you can order for a custom Hole saw made to your size and material.

Classic image of a Hole viewed
(Classic image of a Hole viewed)

2.Why do you need to use a Hole saw?

There are cases when you must use a Hole saw rather than a usual drill when making holes. The following and typical applications of Hole saw:

●CUTTING VENTS IN MASONRY: A perfect use of a Hole saw is to cut through masonry for installing an air vent. A diamond Hole saw is useful in this case.

●MAKING CONNECTIONS IN PIPE: You can also use a Hole saw to make holes in your pipes at different diameters when plumbing.

●DOOR HARDWARE INSTALLATION: When installing a door, you’d often need to make holes in it before installing the hardware. So, you should make use of a Hole saw to drill a smooth Hole for the deadbolts and locksets.

●INSTALLING LIGHT: Hole saw also helps when installing lights. It is a handy tool when you’re trying to create a hole in your ceiling before installing light fixtures and fittings.

●CUTTING HOLES FOR ELECTRICAL CABLES: Electricians also make use of Hole saws when wiring a building. Hole saw is used to cut access points for wiring and cables.

Handyman using a Hole saw to the borehole in the ceiling
(Handyman using a Hole saw to the borehole in the ceiling)

3.What size do you need to punch?

Of course, by now, you should understand that a Hole saw comes in different sizes. When you need a custom Hole saw, you need to know the format you need it. To acquire that, you need to know the diameter you’re trying to create. You can use a meter rule for the measurement effortlessly. Apart from determining the width of the Hole saw, you’d also need to measure it in metric and imperial. Technically, Hole saws come in a wide range of sizes you can select for the task. Typically, Hole saws are between 14mm to 210mm in diameter. However, if what you need is smaller or bigger than this range, you can easily order for a custom hole saw, made to your specification.

Different sizes of Hole saw
(Different sizes of Hole saw)

4.Choice of cutting blades

When picking out a customized Hole saw, you have a wide range of things you can modify, like the choice of cutting edge. Your choice of cutting blade determines the type of material you can use it to cut. Here are some common examples of cutting blade you can pick from:

●Carbon steel hole saw

●Bi-Metal Hole saw

●Single tooth hole cutters

●HSS hole saw

●TCT hole saw

●TCT hole cutters

●Adjustable hole cutters

●Triangular hole cutter

●Diamond grit hole saw

●Core cutter

However, note that these are just the standard cutting blade, but you can make a custom blade for whatever purpose.

A set of carbon steel hole saw
(A set of carbon steel hole saw)

5.Distance selection between the sawtooth

Just like the make of cutting blade is of different materials, the distance between the sawteeth is also different. The distance between the points of two teeth (serrated) is the pitch. The little variable detail might seem pointless at first, but it is very crucial, as it tells on the versatility of the Hole saw. Some Hole saws have more uses than others because of the design of the sawtooth. For example, a constant pitch Hole saw maintains the same distance, while a variable pitch Hole saw varies in its pitch distance.

The advantage of using a Constant pitch hole saw, although it works slower, is that it produces a smooth cut. And a variable pitch breaks the sawing rhythm, which may seem like a disadvantage at first, but it helps prevent vibration so you can have a smoother cut. Variable pitch also reduces the noise level and blade wear.

Drill bits Hole saw for woods
(Drill bits Hole saw for woods)

6.TPI Value selection

To understand what TPI (teeth per inch) value selection means, see it as a measure of tooth frequency along the blade. For instance, if you have a Hole saw with 18 TPI, it also means the hole saw has 18 teeth per inch. The TPI can vary based on your specification and what you need it for, but most times, it stays within the general ballpark of 2 to 20.

A Hole saw cutting blade with higher TPI cuts slowly, but it is less likely to tear the fabric or material as it produces a very smooth cut. On the other hand, when the TPI is lower, it cuts faster, but they tend to tear the material. A low TPI Hole saw cutting blade forms a more ragged edge.

Steel hole saw with different TPI
(Steel hole saw with different TPI)

7.Selection of cutter bar in Hole saw

Here’s where things get even more interesting, as the cutter bar in a Hole saw also comes in different shapes for different uses. The metal cylinder of each Hole saw culminates an edge which makes use of either ultra-hard embedded material, square teeth, or serrated saw teeth to cut through materials.

●COATED: There’s no use of teeth here, instead of an ultra-hard material usually made out of diamond, or tungsten carbide coats the cutting edge.

●SQUARE TEETH: The teeth are set on a farther distance because we prefer raw power in this cutter bar than a smooth cut. A square teeth cutter bar is useful in cutting more abrasive surfaces like brickwork, concrete, and so on.

●SERRATED SAW TEETH: This is typically set at a 60 degrees angle, making it easy to create a penetrating bite into the material.

A serrated saw teeth
(A serrated saw teeth)

8.Hole saw hole size can be changed

Just like the metal cylinder of a Hole saw has a wide diameter range, we can also alter the hole size to your specification. The cutting depth or hole size of a Hole saw is the maximum a Hole saw can cut without using an arbor extension.

Perhaps what you need to create a hole is thicker than what your Hole saw hole size can cut. In such cases, the only way out is to customize the Hole saw a hole to fit that particular purpose. Most Hole saws can cut different depths ranging from 22mm to 350mm, depending on the make and model.

Different hole size of an Hole saw
(Different hole size of an Hole saw)

9.Choice of Drill

Lastly, Hole saws are attached to drills, so your choice of Drill matters a lot in a Hole saw. So, when you want to drill a hole with Hole saws, you must have a good quality drill. When choosing the right Drill, keep an eye out for significant features like the power, the voltage, RPM, and if it uses battery or cable to an electric source or both. There are different types of drills out there, from different manufacturers, with different specifications.

(A pneumatic power drill)


In summary, this guide has pointed out crucial things you need to know before you get a customize a Hole saw. A custom Hole saw comes in handy in helping you achieve that task with ease. A custom Hole saw is useful in so many areas like plumbing, wiring a building, cutting through concrete, amongst others. And with the versatility of the Hole saw cutter edge, sawtooth amongst others you can do even more. Whenever you need to customize a Hole saw, be sure you can get it done at NCCutingtools.

Was this guide helpful in ensuring you know what and what you can alter when requesting a custom Hole saw? Was anything left out? If, in any case, you think or have any other improvement to your Hole saw you feel would help the quality, kindly leave feedback. Feel free to contact us anytime for your custom Hole saw based on your specifications. There is no need to get stuck trying to create a perfect hole anymore.

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