How to cut deep holes or enlarge existing ones with a hole saw?

29th February 2020


How to cut deep holes or enlarge existing ones with a hole saw


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		There may come a time when you need to cut a hole that is deeper than the maximum cutting depth of your hole saw, for example: when cutting a hole through a wall for an air vent installation. To do this you’ll have to complete the job in stages. Read the step-by-step guide below and get in the know.

		How to cut a deep hole with a hole saw
		Step 1 – Cut to maximum depth Use your hole saw and drill to cut to the maximum depth possible. Remember to pull the hole back out every so often so as to clear the chippings and sawdust. If your drill has a side handle, use it to provide a surer, more stable grip.

		Step 2 – Chisel out wood Use a chisel to cut out as much of the wood as possible. This will then allow you to start again with the hole saw and cut deeper. Note: if you are not cutting a through-hole (a hole that goes all the way through your workpiece), chisel out as much wood as possible and stop here.

		Step 3 – Continue cutting Once you have cleared the wood from the hole, align your hole saw and continue cutting to your required depth or until you make a complete through-hole.

		Step 4 – Arbor extension (optional) If you need to a really deep hole then you may need to attach an arbor extension. For more information see the page entitled: What hole saw sizes are available?

		Enlarging an existing hole
		As well as cutting deep holes, you may have to enlarge an existing hole e.g. for a new lock set or door handle. This can prove difficult as the existing hole will make setting your pilot hole impossible. Read this step-by-step guide and the job will be done in no time.

		Step 1 – Clamp scrap wood to workpiece The problem with enlarging an existing hole is that you don’t have a solid point at which to secure your drill bit. By clamping a piece of scrap wood to your workpiece, you can get around this problem.

		Step 2 – Mark your centre Mark the centre of the existing hole on the side of the door so that when you clamp your piece of scrap wood to it you can transfer the mark to the scrap wood and you will know you are drilling the correct place.

		Step 3 – Cut hole With the piece of scrap wood securely clamped, aligned and marked you can now start drilling your pilot hole which will secure the hole saw prior to cutting.