What Is The Best Saw For Cutting A Hole?
The goal of this article is to recommend the best saw for cutting holes. There are several types of saws that can be used to cut holes in various materials. We will compare the most common options and their features to determine which saw is the optimal choice for clean, precise, and efficient hole cutting. Knowing the right tool for hole cutting jobs can save time, effort, and produce better results.
Circular Saw
Circular saws are a very common and versatile portable power tool used for DIY and construction projects (The circular saw – What it is, how it is used, dangers …,” 2023). Their portability, ease of use, and ability to make straight and angled cuts makes them one of the best choices for cutting holes in wood and other materials.
The main benefits of using a circular saw to cut holes are its compact size, lightweight design, and familiarity. Most circular saws weigh less than 10 pounds, with cordless models being even lighter. This allows easy maneuverability and control during use. The basic operation of clamping a straightedge guide in place and running the saw along it is an uncomplicated process familiar to most DIYers and builders.
Adjustable cut depth and bevel functions allow holes to be cut at a variety of angles and depths with a circular saw. Models with laser guides further simplify accuracy. As long as a straightedge is properly clamped to guide the cut, clean and precise holes can be achieved (The circular saw – What it is, how it is used, dangers …,” 2023).
Jigsaw
One of the most useful tools for cutting detailed holes and shapes is the jigsaw. Jigsaws use thin, narrow blades that are able to make tight cuts and curves with precision and control. As noted on Arstechnica, jigsaws are great for cutting holes because the 24 teeth per inch blades provide a clean cut. The narrow blade allows you to maneuver the jigsaw to follow curved lines and templates for intricate cuts.
Jigsaws give you more control over the cut versus a circular saw. As this YouTube video demonstrates, you can cut sharp angles, circles, and scrollwork easily with a jigsaw. The up and down motion of the blade allows better precision than a spinning circular blade. According to The Family Handyman, jigsaws excel at making curves, detailed cuts, and short cross-cuts.
For the most detailed holes, a jigsaw gives the best control and ability to follow a line. The narrow blade and versatility make it possible to cut precise openings and shapes.
Oscillating Saw
An oscillating saw, also known as a multi-tool, can be a good option for cutting holes in tight spaces where a circular saw or jigsaw won’t fit. Oscillating saws have a thin, flat blade that moves back and forth very rapidly, allowing you to make precise cuts. The narrow profile of the blade means you can insert the oscillating saw into tight spaces between boards, studs, pipes, and more. This makes it possible to plunge cut openings and holes even when you only have an inch or two of clearance.
Most oscillating saws also allow you to change out the blade to perform other tasks like sanding, grinding, scraping, and polishing. While the blades are relatively inexpensive, the biggest downside to oscillating saws is that they generally lack the raw cutting power of jigsaws and circular saws. This means it may take longer to cut openings and holes in thicker materials with an oscillating saw. But for tight spots, their maneuverability and compact size can’t be beat.
Reciprocating Saw
A reciprocating saw, also known as a sawzall or demo saw, is a versatile tool that can cut through a variety of materials including wood, plastic, and metal. Reciprocating saws are powerful, with many models putting out 10 or more amps of power. This allows them to cut quickly through thick materials.
Reciprocating saws use a blade that moves back and forth rapidly, enabling very fast cuts. While circular saws spin in a circle, limiting the thickness of material they can cut, reciprocating saws can cut through much thicker materials since their blades move in a straight line. Many reciprocating saws have variable speed triggers, allowing the user to control the blade speed for optimal cutting performance.
With their combination of power and speed, reciprocating saws make quick work of demolition tasks and cutting openings in floors, walls, and ceilings. They are a versatile tool for any major remodeling job. Their ability to make fast cuts also aids in pruning trees or cutting through overgrown brush. For clean cuts in wood, plastic or light metals, a fine-toothed blade should be used.
Hole Saw
Hole saws are one of the most common tools for creating round holes in wood, drywall, plastic, and even some metals. They feature an open-ended cylinder with saw teeth on the end and are driven by an electric drill. According to Home Depot, hole saws create clean, smooth cuts for perfectly circular holes.
The cutting edges of hole saws are made of high-speed steel or carbide, making them ideal for cutting through wood, plastic, or thin sheet metal. As the drill spins the hole saw, the teeth around the perimeter cut through the material and the center drill bit of the hole saw keeps it centered and stable. Hole saws come in a range of sizes, typically starting around 1/4″ up to 6″ or more.
When using a hole saw, it’s important to go slow and steady by allowing the tool to cut at its own pace. Apply only light pressure. Lubricating the saw with oil or lubricant spray can also help minimize friction and heat. Backing the material with a piece of scrap wood provides a zero-clearance surface and cleaner cut.
Step Drill Bit
A step drill bit is another convenient tool for cutting holes, particularly in metal. As the name suggests, these bits have graduated cutting edges in increasing diameters, allowing you to drill a series of increasingly larger concentric holes with just one bit.
The stepped profile makes them perfect for drilling precise, clean holes in sheet metal. You simply start with the smallest cutting edge and work your way up in increments until you’ve reached the desired hole size. This removes the need to switch between multiple standard drill bits.
Step drill bits are ideal for drilling holes in metal up to 1″ in diameter. The graduated steps help prevent jamming in metal and allow you to slowly increase the hole diameter for smoother cutting. They work with any standard power drill and provide excellent control.
Just be sure to secure the metal sheet so it doesn’t spin. Applying firm pressure and cutting oil is also recommended when using a step drill bit for metal. Slow and steady progression through the step diameters produces the best results.
Spade Bit
A spade bit is a good choice if you need to drill relatively large, rough holes quickly and easily. Spade bits have a flat blade tip that is wider than the shank. The flat tip helps guide the bit and keep it straight as you drill. Spade bits come in a range of sizes, typically from 1/4 to 1-1/2 inches in diameter.
Spade bits are designed for drilling in wood. They are quick and easy to use for boring holes for electrical boxes, plumbing pipes, door knobs, or other hardware. However, the holes will not be perfectly smooth or clean cut. Spade bits leave splintering around the edges of the hole that will need to be sanded or trimmed.
Spade bits work best in softer woods. In hardwoods like oak or maple, you may need to back the bit out repeatedly to clear chips. Applying pressure while drilling can cause the bit to wander or deviate off course. Let the bit cut at its own rate without forcing it.
While spade bits are fast for rough holes, they do not offer the precision control of a hole saw or other cutters. If you need a clean, smooth hole with minimal tear-out, a spade bit is not the best choice.
Recommendation
Based on the key factors of versatility, cost-effectiveness, and ease of use, the Milwaukee 49-56-0320 bi-metal hole saw kit is the best overall saw for cutting holes. This set provides a wide range of hole saw sizes to handle different cutting needs, from 1-1/8″ to 4-1/2″ diameters. The bi-metal construction allows these saws to cut through various materials like wood, plastic, and metal smoothly and efficiently. At around $35 for a 21-piece kit, Milwaukee hole saws offer great value without sacrificing durability or performance. Their tooth design and side cooling slots make clean, fast cuts while reducing binding. For DIYers and professionals needing an all-purpose hole saw set for woodworking, metalwork, and other applications, the Milwaukee 49-56-0320 is an ideal choice.
Conclusion
To summarize, the best saw for cutting a clean hole depends primarily on the material, hole size, and accessibility. For wood, a hole saw offers a quick and easy method for cutting precise, clean holes. For metal, an oscillating tool with a hole saw attachment can cleanly cut openings with limited access. Jigsaws work on wood, plastic and thin metal when an exposed blade edge is acceptable. Reciprocating saws cut fast and rough openings in thick materials. And step drill bits bore small, clean holes in metal.
Based on versatility and convenience, a hole saw kit is likely the best all-around saw for cutting holes. Hole saws attach to standard power drills, come in various sizes, cut wood and metal smoothly, and create an enclosed cut for safety. For quality results in most materials while avoiding jagged edges, a hole saw set gives you the right tool for the job.
