How to Cut Perfect Holes in Metal - Kevin Caron

[@tgailw1982]

I don't often sign in just to "like" a video but this one was VERY helpful! In fact, I had seen someone use one of these on wood in a home renovation project but didn't realize you could use them for metal....man, you really learn something new every day! This was just what I was looking for to finish up some mason jar light fixtures that I was making. Thank you, Kevin.

[@WhiteOakAmps]

I appreciate these how-to videos so that for the task that I have to do, I do not go out and buy the wrong, over-priced product when the simple product will do just as well or better. Actually seeing what may be considered extremely simple to other people-- and possibly too simple for a video-- is a quick time saver for me which I really appreciate.

[@bensonryker4798]

Instablaster.

[@Bettinasisrg]

I was laughing so hard, I had to comment. I am a 40(ish) year old woman metal artist just getting into my stride, and always love how concise your explanations are, but during this video (&others) when your wife asks the exact same questions that I have pop into my brain at the exact same time I sometimes think my wild youth is catching up with me! Lol! Thanks again you guys, you always teach me something I need to know.

[@KevincaronSculpture]

Thanks for watching!

[@josstark8124]

Always enjoy your videos and the fact you take the time to create your tutorials with clear explainations. Thanks.

[@tonydeleo7697]

Hi Kevin, great video! With the bigger hole saws I have found it best to spin the saw cup onto the mandrel just until it touches the back part then unscrew it back a half of a turn. This keeps the saw cup from seizing up if it heats up a bit during use.

[@KevincaronSculpture]

Great tip! Thanks for posting.

[@akawireguy1197]

The secret to using holesaws with a hand held drill is to drill the pilot hole with the saw off the mandrel, then install the saw and begin cutting. This gives you control over the saw "hogging in" as the drill bit breaks through and allows you to better center the saw on the work as it begins cutting. Equally important in wood or metal. I like to use an extension cord so I can stand on it at the connection to my drill. This way if the saw hogs in and wraps the cord around your hand you can use your off hand or even a foot to quickly unplug the drill motor. It can be shocking to discover how powerful even a little 1/4" corded drill can be when the bit stops turning and the drill motor spins in your hand and wraps the cord around your trigger finger so you can't shut it off. Not that that has ever happened to me of course LOL.

[@mbud2529]

we used to use the 6" dia saw for cutting the fuel opening for toro gas tanks that were made from hard plastic. these saws are designed to hold the waste so it doesn't drop back in the tank. but keep them sharp!

[@rosendofchavez6341]

First time watching your videos, what a great way to explain metal cutting, I really enjoy them

[@KevincaronSculpture]

+Rosendo F Chavez Thank you..

[@honestinsincerity2270]

Can we just all take a moment to appreciate hole saws? They may piss you off when using a hand drill on the site but, damnit, they're a great invention.

[@KevincaronSculpture]

Amen Brother!!!!!

[@mtrentwood]

Nice plug for Home Depot! My wife's a store manager here in Phoenix...she'll appreciate that!

[@KevincaronSculpture]

Not intended to be a plug, just sharing where I got it.

[@MidtownTrikes]

your videos are very helpful, I have learned a lot from you

[@igiveup240]

thanks for posting this video up Kevin.

[@onbendedkne]

Thanks for the great video. I never knew there was an automatic center punch. Ran out and bought one right away. One thing you didn't mention though was that you can use these bits for wood also. The trick is to make sure when purchasing them that you buy the long or deeper ones. If not and you try to drill through thicker surfaces like a desk top, your bitt won't be deep anough to make it all the way through. Tall works on anything plus they come with a channel on the side so that you can push the core out after cut.

[@dammitdad]

I have not seen an automatic punch either! You learn an awful lot of unexpected things from watching someone else at work. Neither of you would think the other doesnt know this! Keep it up

[@jryer1]

Kevin, wanted to say thanks for the showing the spring loaded punch. Been looking for something like that, very cool.

[@Kopsu87]

I asked my local hw shop for a metal hole saw. They had holesaws like yours and they told me that they are designed for wood and will do the job for a while, but will quickly destroy the cutting edge. For metal holes they had this christmas tree looking drill bit which is only able to cut up to 3cm diameter hole. I bought neither, since I need to make bigger holes, at least up to 5cm. Obviously they just had a bad selection and I need to find holesaws with metal edge like yours. I wish there was adjustable one though, those sets can be rather expensive. Thanks for the vid.

[@thepoultrypeople]

***** seriously, these are the same as the wood cutting hole saw kits i see? so go slow and use a coolant? thanks for sharing!

[@Kopsu87]

***** thepoultrypeople I bought a set of 8 hole saws. They were designed for wood/plastic etc. lighter materials. I tried to saw through a very thin metal Ikea bowl (for DIY lamp project) and failed miserably. I used WD40 as fluid since I didn't have anything else at the time and went very slow. The blade is completely destroyed and I didn't even manage to make the hole. After this failed attempt, I bought one of those bi-metal hole saws and it did the job perfectly. The first set I bough was only 8€, so I didn't lose much.

[@thepoultrypeople]

thank you, im going to be ordering a set once my pillar drill arives, well, once ive found an old pillar drill thats worth buying that is :)

[@kevinandivy]

I m sorry but the cheaper saws designed for wood will not last long on metal. You need whats called a bi-metal hole saw. Its designed to take the heat.

[@kevinandivy]

Kopsu If the saws Kevin is using are lasting and cutting then they are bi-metal saws and he just thinks they are just wood cutting saws and he may not know the difference.

[@oldcountry220]

I find if you drill a pilot hole and replace pilot bit with a smooth rod of correct diameter prevents chatter and run out when using a hand held drill.

[@KevincaronSculpture]

Have to give this a try! Thanks for watching and posting.

[@Flicklix]

***** , I'm needing to cut a 2" diameter hole into the side of a 16qt. aluminum stock pot (close to the bottom of the pot). Any hints on cutting a hole into such a curved surface? Thanks!

[@electricbadgercollc8146]

Thanks for posting your video. Now, could you show how to cut through steel (not just aluminum).

[@KevincaronSculpture]

Same way! Same tools, you just have to cut a little slower.

[@meTimetraveler]

i almost broke my wrist with a hand held 1/2 in. drill and a large whole saw ...2in maybe 3 in in wood when it jammed. i would recommend using a drill press. Maybe using both hands too if not a drill press

[@KevincaronSculpture]

Hate it when that happens! Stay safe out there!

[@garyg2460]

Really enjoy your video's Kevin

[@KevincaronSculpture]

Thanks for being on the other end of the internet!

[@coburnlowman]

I know all there is to know about holes😂. I was a tool maker and made strike and progressive dies. I got the high school and tech school students to work with and train. One kid came in and I asked if he was taking tool making. He laughed and said "NO! because all they do is teach how to use a surface grinder and I know all about that already" I gave him the print to a complex punch with all sorts of angles and blending angles. He never got anything close to the print and never did loose the cocky attitude. We gave him a couple of months and sent him on down the road.

[@bowlweevil4161]

Kevin look at the hf drill press locking clamp, it fits in the slot in drill press table it's adjustable to lots of stuff that you will drill I don't take mine off the table unless i have to drill something bigger than table it will also clamp your vice in place quickly good vid THANX

[@KevincaronSculpture]

Thanks for the heads up! Will check it out!

[@stevehammel2535]

I enjoyed your video and learned a lot

[@fredm2786]

Awesome video thank you very much 😎👍

[@KevincaronSculpture]

Thanks for the visit

[@dylanlatest109]

keep up the great work Kevin

[@scor440]

Are the holes to the size listed on the cutter after the hole is cut?

[@KevincaronSculpture]

Yes, that is the size you get.

[@boyan2712]

Kevin, Thank for video. Maybe you know how to make disc from stainless steel plate(1mm) dia 30 to 60mm?

[@KevincaronSculpture]

I would just cut it out of a sheet. Or do you mean a dish? Then you need a wheel or a shaper.

[@boyan2712]

I need small disc different diameter(30,40,50,60mm).It is different thickness(1mm, 0,5mm,or 0,7mm). I need this small disc, for keyring pendant

[@junglejammer1]

I like your videos. Lots of good tips. I have one of those Borg Warner cabinets, exactly like your's, in my shop too.

[@gga347]

Thanks for the video. I wonder if you can help. I need to enlarge the two tap holes in a steel bath from 38mm(about 1.5") to 44mm (about 1.75") as neatly as possible. There is obviously nowhere for the pilot to go. How could you do that job, or is it a job best left alone? FYI: The reason is to fit a special kit to make it possible in the future to replace the bath shower mixer tap assembly without the awkward job of going behind and underneath the bath to access the plumbing. Thanks for any advice you can give. Chris.

[@gga347]

***** Thanks Kevin..interesting idea. I thought of another possible way. I have rubber bungs that go into demijohns for home brewing. They are just about the same size as the tap holes and have a hole in the middle for a bubbler airlock. They taper in width slightly towards the bottom like upside down truncated cones. Once wrapped in some duct tape they fit tightly low down into the holes with only a little showing above. The hole in the bung is similar in size to the pilot drill....just a thought!

[@mmmmmmmw368]

hey kevin, you could try an electricians ko punch set for a faster cleaner hole up to 4"

[@KevincaronSculpture]

+Miriam Lutz Still looking for a good set at a cheap price...

[@paulastbury11]

kevin i just watched you hole cutting i want to cut 5mm of steel and i want to cut 39mm hole and then a 46mm hole on the outsde of it to make a circle ie a wheel could i use these drill bit to do this

[@KevincaronSculpture]

Yes, you can. just do the outside first then the inside.

[@CertifiedGasSystems]

I need some 2" round pieces from 10 gauge metal (the center after the cut). How do I get these without the drill hole in the middle? I don't want the holes, I want the centers. So far I just fill in the drill hole with my welder and grind even but would like to eliminate this step and keep the heat off.

[@KevincaronSculpture]

Use a drill press. Clamp your metal to the table over a piece of wood and take the drill bit out of the center of the hole saw. Go slow and use cutting oil.

[@ThetaPower]

Nice video. Thanks. I need to make a "washer" that has a 3" OD and a 2" ID. I have not found these for sale. So I thought I would use a Greenlee Slugbuster Knockout to open up a 3" x 1 5/8" washer. The washers I found on McMaster Carr are only 0.13 thick -- just shy of the 10 gauge these cutters are rated for. The washers are not hardened and are just zinc coated steel. What do you think? Would you try the hole cutter first? Not sure how to hold the washer while cutting.

[@KevincaronSculpture]

Never used one of those cutter so can't offer an opinion. I would probably use a hole saw with the washer clamped to the table some how...

[@ehabalrobaie6832]

thank you Mr KEVIN from Iraq

[@KevincaronSculpture]

Thanks for watching and posting!

[@ehabalrobaie6832]

Yes I hope to learn more and more

[@jtbmetaldesigns]

Kevin, I love your videos! You have got me out of minor jams in my metal explorations many of times. I know you say to use a drill press at larger than 1 1/12" but I have not yet got one. Would I be safe clamping the work piece on my welding table supported by scrap timber with my hand drill?

[@alx2025]

Hello Kevin. Would those hole saws cut 10g metal?

[@KevincaronSculpture]

yes they will! Have holed 1/2 inch plate with them .

[@alx2025]

Kevin Caron, Artist ok thank you for the info.

[@jonryan391]

Any tips to do that with an Everlast plasma cutter?

[@KevincaronSculpture]

I just use the hole cutter guide.

[@JohnDrach]

At what thickness of aluminum would you say is to think for these type of bits? I am making a skid plate and I want to make sure I can cut through it. Would 1/4 be way to thick for these bits?

[@Longboardsinglefin]

***** Kevin, I've seen a guy demonstrate this on KZbin. He cut 1/2" steel by holding the nozzle of a vacuum cleaner close to the blade teeth. The vac took away the swarf, and kept the teeth perfectly cool. Amazing!

[@mangreat71]

What tool to use to cut through a clay flower pot, i just need a very small whole just to use a nut and a bolt ?

[@VictoryAviation]

Awesome Q&A. You rock!

[@xoukilong]

I gotta cut a hole in my steel garage door for an exhaust port. Going to use this method.

[@KevincaronSculpture]

Good luck!

[@MrWelder43]

Nice video.I use 75% water 25% soap detergent in a spray bottle as a lubricant to keep the blade cool & lubircated.You don' have that oily mess to clean up after wards.

[@1pcfred]

You can add a bit of oil to your mix and have an emulsified cutting fluid.

[@SuperBardley]

This is good to know, but what is the value of an emulsified cutting fluid vs. straight cutting oil vs. the proposed soapy water vs. Astro-Glide?

[@1pcfred]

Emulsified oil is a lot cheaper than straight oil by volume. Plus I imagine it has better cooling properties. Soapy water is not going to lubricate metal nearly as well as oil does. We ran straight 30 weight oil on our broach in the shop where I worked. That machine had a 500 gallon reservoir in it, and the oil would get hot over the course of the day. Milling machines had 10 gallon emulsified tanks. They stayed cool too.

[@SuperBardley]

Thank you. Years ago, I used a horizontal bandsaw w/ emulsified oil and it worked great -- water has a very high thermal coefficient, which is why it can absorb so much heat before actually warming up itself. How do we DIY emulsified oil? Also, does the water component contribute to corrosion or does the oil keep that at bay?

[@1pcfred]

Homemade emulsified cutting fluid is water, detergent, oil, and alcohol, or some other suitable de-foaming agent. Detergent proves the old adage of oil and water not mixing wrong. But when you mix soap and water you end up with a lot of bubbles. So alcohol acts as a surfacant to break up the foam. The amount of oil used controls corrosion. Although you do have to clean up. You end up with organic cutting fluid with this formula. It looks like the white kind of coolant.

[@ESLinsider]

I tried making a circle cutting jig for jigsaw that I see weveryone make but it's not working for me. It will bend the blade and eventually snap the blade outside the guide. Hole saw looks better but crazy espensive. A 6 inch holesaw at Lowes was like $60.

[@KevincaronSculpture]

Oh no!l Sorry to hear that. Tell me what you are doing and maybe I can figure out a way to help. Are you using too wide of a blade maybe? What are you cutting? How fast are you running the blade and how hard are you pushing?

[@jy7duality]

Great video, thank you. This helped me out quite a bit

[@KevincaronSculpture]

Thanks for watching!

[@PBS-nm1uu]

for the metal on the table what is the life span of the blades??

[@KevincaronSculpture]

I get years out of a blade. Probably in the 100s of cuts.

[@Metalhead-4life]

Kevin I need to cut a 1" hole in my pc case but the problem is the top of the case already has small oval holes in it for air flow. How (what tool) can I use to cut a perfect hole??? Im afraid a hole saw or step drill bit might not work or it might walk because of the premade holes.

[@Metalhead-4life]

That answers how but not WHAT. My question is WHAT TOOL should i use??? Because the metal is like a thicker gauge steel mesh with oval not round holes I am afraid a hole saw or step bit might catch on the holes and tear it up. What tool is best for this job? thanks I appreciate your time and help! Here is a pic of the case im cutting. 3rd picture down: techreport.com/review/25410/corsair-obsidian-series-750d-case-reviewed/2

[@MrNikstar89]

Hei Kevin. Thanks for the video. I am wondering if you can help me with this one: I want to cut a ca. 100mm hole into a 1mm metal plate (mild metal). The plate is too large to fit a drill press that i could borrow. Do you suggest i try a hand held drill with a 100mm hole saw, or will that be difficult? Also read stuff about thin metal such as this is difficult to process with hole saws. What is your experience on that? Thanks in advance.

[@KevincaronSculpture]

Try using the hand held drill with a block of wood on the other side of the metal to drill in to.. That will keep the drill from wondering.

[@SAXONWARLORD1000AD]

Do you think i could do a 4 or 5 inch hole in the side of my jeep for a gas filler relocation - obviously vertical sheet metal with hand held drill??

[@KevincaronSculpture]

Find some way to clamp a block of wood on the back side of the panel. That will give the saw something to guide on and keep it from wondering around. Go slow and you should be fine.

[@tedijune6759]

@@KevincaronSculpture This is helpful to me as well :-). I’m cutting a 4” circle in the sidewall of my stackable washer- Dyer to save walkspace, but still have proper venting :-)

[@freshcaughtbass]

what material is the "ladybug wing" made of...? aluminum, mild steel? I assume the hole saws can't touch stainless

[@KevincaronSculpture]

+freshcaughtbass Just mild steel,, 16 ga. if I remember right.

[@TheCerberusInferno]

I know how to cut a perfect circle but the problem with my saw is the very big noise , is there any way to cut metal without ( or limitate ) this problem ?

[@KevincaronSculpture]

+Kami Star Great question! Go slower will reduce the noise somewhat but you have to go really slow...

[@TheCerberusInferno]

+Kevin Caron, Artist Thanks for your answer Kevin .

[@GUNVALKERIE]

I know that you used a specific type of big drill bit to make a circle into sheet metal but is there a way to make perfect holes using a basic 1/4" drill bit into 2mm to 3mm aluminum sheet metal... I'm trying to do this to heat sink aluminum

[@KevincaronSculpture]

+GUNVALKERIE Drill it just under the size you want and get a reamer to true the hole with...

[@brunolaflamme5202]

My small concern is about managing the rpm on my hand drill 9 amp to prevent from overheating and the best cutting fluid I can get?

[@KevincaronSculpture]

+Bruno Laflamm There are many good cutting fluids out there... check with the folk at MSCDIRECT.COM they can steer you in the right direction... Or just use old automatic tranny fluid. I hear that works pretty good....

[@timkindle7508]

at what speed would you suggest running the drill press at?

[@timkindle7508]

Do you know what RPM that would be?

[@kristycontreras444]

Thank you Kevin!!! Just the info I needed!

[@KevincaronSculpture]

Thanks for watching!

[@twistedoar]

any tips on cutting 2.5 and 3" holes in stainless sheet metal?20ga.

[@KevincaronSculpture]

+twistedoar Good cutting oil and go really slow!

[@Mrflashlite]

Good video, the one problem that I did see was that you keep your pilot bit too far out past the teeth of the hole saw, they have a set screw on the side of the mandrel so you can adjust the bit for the thickness of the metal you are drilling through (these are special bits with a flat on them so be sure that it is turned right and the set screw is tightened against the flat). This is fine in thin metals and aluminum but if you are drilling into mild steel, brass or stainless steel especially if you are using a hand drill the pilot bit will grab as it penetrates and exits the metal and jerk the hole saw into the material and damage the teeth on the hole saw itself.

[@Mrflashlite]

I like your videos, keep them coming.

[@adrianogomes1871]

Great video Thank you very much

[@KevincaronSculpture]

Glad you liked it!

[@jakepascual6018]

Skip 5:54

[@nestorlima7651]

GOOD EXPLANATION.

[@KevincaronSculpture]

Glad it was helpful!

[@1970chevelle396]

Harbor Freight sells a hydraulic Hole Punch. I think it sells for $120. It punches holes in 1/8 plate real well.

[@kirkwesterveltoutdoors]

Ha Kevin you just showed me how to use a hole saw.....wow

[@KevincaronSculpture]

Thanks for watching and posting Dick!

[@LESTERBATE]

The little attachment you refer to is called a mandrel.

[@JoshuaG85]

Ok, this is a different subject I am going to ask. I came here, after looking on metalfreak. I want to make a submarine. Well, the top half. It is a mailbox idea I have. I will make it with aluminum. I guessed, that I would need to make the inside structure with three half circles. Front, middle and back. Then, put square tube on the top left and right and side left in right. The thing would be at least three feet long. But, being new to welding, how can I get aluminum bar to make a circle? Haha. Is that a dumb question? I imagine it would be tough to bend the stuff. Can I make cuts that will make it be a perfect circle? I would then out I guess a sheet of aluminum over each side to make the main sub base. Just a random question.

[@KevincaronSculpture]

Bend the flat sheet to make the shell and add a cross brace to stiffen it.. Then cut half circles to make ends and rivet them in place. Bend square tube can be done but not by hand.. Google "tube rollers" and look for the square dies to go with it..

[@JoshuaG85]

That makes sense. haha No sure what rivet is. haha GOOGLE! I am going to email you my first idea. But, yours seems much better. I mean, it's like you've done this before. haha

[@stuarth43]

TIP, AFTER FIRST DRILL TAKE OUT YOUR 1/4 DRILL AND CUT A SCREWDIVER BIT TO FIT, IT WILL NOT BREAK, done big holes in heavy plate

[@ypaulbrown]

Kevin, nice video, you can also sharpen holesaws with a .045 cutoff disc in your angle grinder...just clamp the grinder in a vice and turn on, put the teeth on the disc and away you go, this can be done multiple time.....I found this out cutting 1 1/2 " cast iron......where I had to cut 75 holes......best regards, Paul

[@gachitadamunga2403]

Thank you

[@desalvo66]

where in the world do I purchase a 10" hole saw that doesn't cost $370.00..?

[@KevincaronSculpture]

I think it's called a jigsaw.

[@bernibeckmann9753]

desalvo66 You might have to use a couple of those $185 5 inchers. Hope that helps!

[@PowerGearPerformance]

Chinese plasma cutter for $197 is the best option long term

[@REDHOTSPAM]

How does this set look to you? Drill Warehouse 13Pcs 16mm-53mm Stainless Steel Carbide Tip TCT Metal Drill Bit Hole Saw Set www.amazon.com/dp/B06XPN3PTY/ref=cm_sw_r_cp_apa_yK1Ozb4SCPS1J

[@KevincaronSculpture]

Looks like I am going to buy a new set! Thanks for the tip!

[@davidsimmons5936]

4000 watt punisher 8 inch subwoofer

[@KevincaronSculpture]

Crank it up!!!!

[@mbot1987]

Excellent!

[@davidsimmons5936]

I'm going to try cutting 7.76 inch speaker hole what ever that means 1 16 passed 7 3/4

[@KevincaronSculpture]

Slow and steady is the way to go. Lots of clamps and cutting fluid will help for sure.

[@CharlesStruble]

Title of this one kinda scared me. Thinkin' "If I ever did something perfect on a project, it's gonna make the rest of it look, well, even more imperfect. Guess I can forgive me for a perfect hole using this technique. Thanks, guys...

[@ابوراكان-ي3ي]

👍🏼

[@piron416]

lucky dude. your wife is helping you.

[@KevincaronSculpture]

+piron416 I am very lucky!! and she is a big help with everything in the background...

[@everycoLor_312]

✌🏼👩🏼‍🎨👍🏼

[@ابوراكان-ي3ي]

👍🏼

[@JamesBond-vq3ky]

Good vid

[@robotmotor]

Great Bro thanks

[@rijivit]

amazing

[@brianwynn5081]

the "little attachment" is called an arbor

[@brianwynn5081]

hahahahahahahaha ;)

[@jeremyhowes8059]

I would rather have seen how you cut the larger holes.

[@KevincaronSculpture]

Same procedure as the smaller holes.

[@Xxmyarek17xX]

great tool

[@romanaangersbach1176]

I made it with woodprix handbooks !

[@Journeyman1642]

I think 99.99% of the human population knows and understands how to use a hole-saw? 🥴

[@KevincaronSculpture]

You would be surprised!

[@creaturecat1]

whats the point of you talking,when we want to see it done! from the smallest whole cutter to the gigger one

[@rfn944]

They are expensive, 40 bucks for a 5".

[@scottydntno]

+rfn944 That's because it's a 5". But how about that warranty? Can't complain. You get what you pay for. :-D

[@patrickchmbrs]

mandrel

[@patrickchmbrs]

no problem .great videos, cheers

[@th-wp7zc]

this video could be 10 seconds easily...

[@KevincaronSculpture]

What fun would that be?

[@th-wp7zc]

Kevin Caron, Artist actually I hate American fast and hasty life style... but you just talked too much in this video. no offence.

[@will01r]

I find it very odd, why America still use imperial in most things from measurements, to weight to distance. It's awful the metric system is far superior.

[@1pcfred]

The USA is a free country so citizens can choose to use whatever they want to use. Officially due to NATO treaty alliances the US government has been metric since 1964.

[@twbrkfd1733]

Not with 316 18 gauge stainless steel!

[@KevincaronSculpture]

If you say so.