Simple Hole Saw Drilling Guides

[astroracer]

I run into this problem quite a bit. Lets say I have an existing hole that is 1" in diameter. I need it to be 1 1/2" in diameter. Using a hole saw is the best way to cut the new diameter but the existing hole is way to big to allow using the typical 1/4" diameter drill to guide the saw. This is what I do to get around that problem.
I use a scrap piece of deck board, 2 x 4 or 2 x 6 to guide the saw.





Cut a hole thru the scrap with the saw you need to use. Clamp the new "drill guide" to your work surface in position over the existing hole. Now cut the new hole with the hole saw. here I am using a Rota-Broach.

No wandering or sloppy cuts. Makes for a nice cut right where you positioned it. I use these when I need a nice cut in thin sheet metal.

[astroracer]

You can see a previously cut hole in this pic.

I needed clean edges because these holes were getting the dimple die treatment.

This is the lower rad mount for a van I am building.

[kbalch]

Thanks astroracer! I've added your Hole Saw Drilling Guides to our Drilling and Drill Presses category, as well as to your builder page: astroracer's Homemade Tools. Your receipt:

Hole Saw Drilling Guides by astroracer

tags: guide, hole saw

[DIYer]

That's a neat jig!

[astroracer]

Thanks! I have been using these for years. Just used one of them the other day and thought it may be a good tool to post. It does make for cutting neat holes with a hole saw and works really well with the Rota-Broaches.
Mark

[Christophe Mineau]

Good idea !

[kbalch]

Kitty is an ugly spam ...

Yep. Deleted and banned. We receive those posts occasionally (all forums are susceptible, to varying degrees, no matter the anti-spam protections in place), though we strive to address them before any of our valued members are troubled.

Sorry you had to see that

Ken