Hole saws come in different types and sizes, and it can be very difficult and confusing to determine what type is needed for your project. To avoid damaging materials and spending money you don’t have, you must have a hole saw size chart in hand.
In this article, we will share what you need to know before dealing with 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 fundamental difference between hole saws is their material. They are classified according to their tips/blades. Hole saws include:
- 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
Although they don’t quite live up to the durability of their bimetal counterparts, these hole saws nonetheless serve a useful role around the house or in a small workshop. As a result of the material’s properties, carbon steel hole saws can only be used for very lightweight tasks.
Carbon steel hole saws can be used in various materials, including drywall, plywood, plastic, etc.
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.
Our Top Recommendation:
Comfecto Bi-Metal Hole Saw Kit
If you prefer drilling clean and accurate holes, the best you can do is buy drill bits made with durable bi-metal steel like the ones from Comfecto. These pieces have high-quality teeth that can hole through any metal or wood.
They have fine-toothing designs that can operate smoothly, so you don’t have to worry about them getting stuck on the material. This kit will also give you access to suitable bits for different 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 our pro woodworkers 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. Premium hole saw brands typically come equipped with universal arbors that can be used 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.
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