Hole saws have a variety of types and sizes, and can indeed be a challenge to navigate. Selecting the wrong one can risk material damage and unnecessary expenses. That’s why I always stress the importance of having a hole saw size chart on hand.
In the following discussion, I’ll share insights and expertise on what you should know before diving into the world of hole saws.
What are Hole Saws and How are They Used?
Hole saws can cut through drywall, steel, aluminum, wood, and more. They are used to pierce circular holes for projects requiring precise and clean cuts.
You can use a standard drill with spade bits for larger holes with 1″ in diameter. But for bigger holes, you will need to utilize hole saws.
Most hole saws have a collar, driving pins, a pilot bit, and a shaft on an arbor or mandrel. First, you attach the hole saw to the arbor with driving pins. Then, insert the arbor shaft into a drill to use the hole saw. The arbor’s pilot bit removes a pilot hole in the piece.
Different Hole Saws Available Today
The core distinction between hole saws lies in their material, especially when you look at their tips or blades. Here’s a breakdown of the types of hole saws based on this classification:
- Gulleted Hole Saw
- Hole Cutter
- Smooth Cut Hole Saw
- Welded Shank Hole Saw
- Bimetal Hole Saw
- Tungsten Carbide Tipped Hole Saw
- Diamond Edged Hole Saw
- Carbon Steel Hole Saw
- Circular Tile Hole Saw
- Cobalt Hole Saw
Bimetal
A bimetal hole saw is, as the name implies, composed of two metals. The frames are often carbon steel, whereas the teeth are high-speed steel.
They are commonly used to drill holes in various materials, including metals, plastics, and wood.
Tungsten Carbide
Carbon Steel
To increase durability, the teeth of these hole saws are typically coated with carbide. The result is exceptionally long durability and quick cutting action.
Carbide hole saws with normal teeth can be used on non-ferrous metals [1], hardwood, plastic, etc. But the one with the gulleted square teeth is even more durable and may be used on bricks, concrete, marble, etc.
My Top Recommendation:
Comfecto Bi-Metal Hole Saw Kit
When it comes to drilling clean and precise holes, I’ve always leaned towards drill bits crafted from robust bi-metal steel, much like the offerings from Comfecto. These bits boast top-notch teeth capable of piercing both metal and wood with ease.
Their fine-toothed design ensures smooth operation, eliminating concerns of jamming or getting stuck in the material. Investing in such a kit also broadens your toolkit, equipping you with the right bits for diverse projects.
- High-quality bi-metal material
- Suitable bits for metal and wood
- Ten different pieces of drill bits
- Padded and secure bag inclusion
Size Charts for Hole Saws
Even hole saws come in a wide range of sizes, much like most other common power equipment. The smallest diameter of the materials I’ve used is 5/8 inches, and the largest is 6 inches.
Remember that size charts provided by manufacturers are your best bet for obtaining precise measurements, especially when you want to know the accurate hole saw size for your door knob. Down to the part number, they provide you with all you need to know.
Hole Saw Sizes for Bi-Metal Material
Diameter | Max. Cutting Depth | Pipe Tap Size | Pipe Entrance Size | RPM | ||||
inch | mm | inch | inch | inch | Steel | Iron | Non-ferrous | Plastic |
5/8 | 16 | 1-5/16 | — | — | 550 | 365 | 730 | 880 |
3/4 | 19 | 1-7/16 | 1/2 | 3/8 | 460 | 300 | 600 | 740 |
7/8 | 22 | 1-7/16 | 3/4 | 1/2 | 390 | 260 | 520 | 640 |
1 | 25 | 1-7/16 | — | — | 350 | 235 | 470 | 560 |
1-1/8 | 29 | 1-7/16 | 1 | 3/4 | 300 | 200 | 400 | 480 |
1-1/4 | 32 | 1-7/16 | — | — | 275 | 180 | 360 | 440 |
1-3/8 | 35 | 1-7/16 | — | 1 | 250 | 165 | 330 | 400 |
1-1/2 | 38 | 1-7/16 | 1-1/4 | — | 230 | 150 | 300 | 370 |
1-5/8 | 41 | 1-7/16 | — | — | 210 | 140 | 280 | 340 |
1-3/4 | 44 | 1-1/4 | 1-1/2 | 1-1/4 | 195 | 130 | 260 | 320 |
1-7/8 | 48 | 1-1/4 | — | — | 180 | 120 | 240 | 290 |
2 | 51 | 1-1/4 | — | 1-1/2 | 170 | 115 | 230 | 270 |
2-1/8 | 54 | 1-1/4 | — | — | 160 | 105 | 210 | 260 |
2-1/4 | 57 | 1-1/4 | 2 | — | 150 | 100 | 200 | 250 |
2-3/8 | 60 | 1-1/4 | — | — | 140 | 95 | 190 | 230 |
2-1/2 | 64 | 1-1/4 | — | 2 | 135 | 90 | 180 | 220 |
2-5/8 | 67 | 1-1/4 | 2-1/2 | — | 130 | 85 | 170 | 210 |
2-3/4 | 70 | 1-1/4 | — | — | 125 | 80 | 160 | 200 |
2-7/8 | 73 | 1-1/4 | — | — | 120 | 80 | 150 | 180 |
3 | 76 | 1-1/4 | — | 2-1/2 | 115 | 75 | 140 | 180 |
3-1/4 | 83 | 1-1/4 | 3 | — | 105 | 70 | 140 | 170 |
3-1/2 | 89 | 1-1/4 | — | — | 95 | 65 | 130 | 160 |
3-3/4 | 95 | 1-1/4 | 3-1/2 | — | 90 | 60 | 120 | 150 |
4 | 102 | 1-1/4 | — | — | 85 | 55 | 110 | 140 |
4-1/2 | 114 | 1-1/4 | — | 4 | 75 | 50 | 100 | 120 |
5 | 127 | 1-1/4 | — | — | 65 | 45 | 80 | 110 |
5-1/2 | 140 | 1-1/4 | — | —- | 60 | 40 | 75 | 100 |
6 | 152 | 1-1/4 | — | — | 55 | 35 | 70 | 90 |
Hole Saw Sizes for Carbide Tipped Material
Diameter | Pipe Tap Size | Pipe Entrance Size | |
inch | mm | inch | inch |
3/4 | 19 | — | 3/8 |
7/8 | 22 | 3/4 | 1/2 |
1 | 25 | — | — |
1-1/8 | 29 | 1 | 3/4 |
1-1/4 | 32 | — | — |
1-3/8 | 35 | — | 1 |
1-1/2 | 38 | 1-1/4 | — |
1-5/8 | 41 | — | — |
1-3/4 | 44 | 1-1/2 | 1-1/4 |
1-7/8 | 48 | — | — |
2 | 51 | — | 1-1/2 |
2-1/8 | 54 | — | — |
2-1/4 | 57 | 2 | — |
2-3/8 | 60 | — | — |
2-1/2 | 64 | — | 2 |
2-5/8 | 67 | 2-1/2 | — |
2-3/4 | 70 | — | — |
2-7/8 | 73 | — | — |
3 | 76 | — | 2-1/2 |
3-1/4 | 83 | 3 | — |
3-1/2 | 89 | — | — |
3-3/4 | 95 | 3-1/2 | — |
4 | 102 | — | — |
4-1/4 | 108 | — | 4 |
4-1/2 | 114 | — | 4 |
4-3/4 | 121 | 4-1/2 | — |
5 | 127 | — | — |
5-1/2 | 140 | — | — |
6 | 152 | — | — |
FAQ
What size of hole saws do electricians use?
Electricians use 2- to 7-inch hole saws. Larger sizes are utilized for recessed can lights and 2-inch saws for feeders. You need a kit between 50 and 90mm for recessed lighting to drill joint feed holes.
Do all hole saws use the same arbor?
No, not all hole saws use the same arbor. An arbor might only work with a specific brand of hole saw, especially if it has an incorporated shank. In my experience with premium hole saw brands, they usually have universal arbors that are compatible with drill bits from any manufacturer.
Conclusion
The hole saw is a unique device. In materials as varied as metal, gypsum, plastic, wood, and more, they make quick work of drilling holes as large as 6 inches in diameter.
However, precision is key to successfully using the tool. Thus, users must reference a hole saw size chart before starting any project involving a hole saw.
You've probably seen his down-to-earth wisdom in USA Today, Bobvila, Family Handyman, and The Spruce, where he has shared commentary and guidance on various woodworking topics.
Robert is the brain behind Sawinery, where he aims to share tips, tricks, and a passion for all things carpentry.
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