Tiny Hole Saw

  • Advertise with us

« back to Power Tools, Hardware and Accessories forum

Forum topic by Peter Oxley posted 01-04-2011 06:58 PM 14642 views 0 times favorited 14 replies Add to Favorites Watch
View Peter Oxley's profile

Peter Oxley

1426 posts in 4016 days

01-04-2011 06:58 PM

Topic tags/keywords: question hole saw

Imagine the shape a hole saw without a pilot bit would cut – a round slot. I need to cut a round slot .25” outside diameter and leave about a .222” post in the center.

I’ve been searching for tiny hole saws, with no luck. Does anyone know where to find tiny hole saws?

Alternately, I’ve been thinking about getting 1/4” thin-wall tube and cutting saw teeth in the end. Any thoughts?

-- -- --

14 replies so far

View hObOmOnk's profile


1381 posts in 4269 days

#1 posted 01-04-2011 07:16 PM

Something like the following might work:

Lee Valley

-- 温故知新

View ptweedy's profile


75 posts in 3535 days

#2 posted 01-04-2011 07:20 PM

I think that makeing a hole saw with a piece of tubing is the right way to get the tool. Next, to position the saw, overlay a piece of material with a hole the correct dia. and clamp it down. Then drill.

View Dennisgrosen's profile


10880 posts in 3257 days

#3 posted 01-04-2011 09:15 PM

Ptweedy :
I have used a simular way of duing it , thow instead of a saw made of tube
I used a normale holesaw for drills and did take the center drill out of the holesaw

I have seen a tubesaw used in a brace , he make the first copple of rounds backward
simular to when when you start anyother sawcuting
but how accurate it was I don´t know , I did looked at some distance

well get us updated with your little project there :-)
maybee you will come up with another solution


View MrsN's profile


987 posts in 3668 days

#4 posted 01-04-2011 09:20 PM

Would a plug cutter like Hobomonk suggested work?

View richgreer's profile


4541 posts in 3216 days

#5 posted 01-04-2011 09:43 PM

In theory, you could do this with a router and a circular template that router sets in. You would “walk” the router around the circular template. This would work a lot easier if you had a round bottom on your router.

-- Rich, Cedar Rapids, IA - I'm a woodworker. I don't create beauty, I reveal it.

View Peter Oxley's profile

Peter Oxley

1426 posts in 4016 days

#6 posted 01-04-2011 10:27 PM

Thanks for the feedback, everyone.

I must not have explained it very well. Plug cutters leave about a .125” gap. The smallest router bit I have is .125”, too. The slot I need is very narrow – about .014” (a .222” post in a .25” hole). I haven’t tried it, but a drinking straw might fit tightly in the round slot I’m trying to cut.

Maybe I should have started out by saying what was going in the slot: inking nibs.

-- -- --

View DaddyZ's profile


2475 posts in 3182 days

#7 posted 01-04-2011 10:32 PM

Why not drill the Hole, then fill in with a dowel (Sanded down of course)

You could even leave a half moon shape if you wanted

Sorry Bentlyj Great minds etc ;)

-- Pat - Worker of Wood, Collector of Tools, Father of one

View Peter Oxley's profile

Peter Oxley

1426 posts in 4016 days

#8 posted 01-04-2011 10:42 PM

I had thought of gluing in a dowel, and it may come to that. But I’d prefer to saw the hole because I want to make several of these, so fewer steps is better (hole saw vs. drill, turn, glue). Also, it seems like it would be hard to avoid getting glue on the walls of the slot when inserting the dowel.

-- -- --

View scottb's profile


3648 posts in 4469 days

#9 posted 01-05-2011 02:36 AM

could try to “modify” a plug cutter. either by grinding down each leg one at a time, or possibly with diamond files while it’s spinning slowly on the drill press or lathe. might be a dremel tool thin enough too?

-- I am always doing what I cannot do yet, in order to learn how to do it. - Van Gogh -- --

View Edziu's profile


151 posts in 3193 days

#10 posted 01-05-2011 02:42 AM

I’m not positive, but I think this would work. The slot it leaves might be a tad big, but it wouldn’t be awful sloppy like a plug maker

View Bob #2's profile

Bob #2

3810 posts in 4163 days

#11 posted 01-05-2011 04:13 AM

These might work.

-- A mind, like a home, is furnished by its owner

View rance's profile


4263 posts in 3302 days

#12 posted 01-05-2011 04:50 AM

Maybe silver-solder an older inking nib to a 0.222” metal dowel, nib pointing up. Leave the butt end sticking out past the metal dowel. Shape the butt end into a cutter like:

Run it in a drill press real fast and take light cuts.

-- Backer boards, stop blocks, build oversized, and never buy a hand plane--

View TopamaxSurvivor's profile


18373 posts in 3818 days

#13 posted 01-05-2011 09:19 AM

Dependiing on what you are trying to cut and how hard it is, a .223 Remington case chucked up in a drill press with teeth filed on it should cut about what you want. The cheap ammo even has steel casings.

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View Peter Oxley's profile

Peter Oxley

1426 posts in 4016 days

#14 posted 01-05-2011 03:59 PM

Great ideas, everyone! I’m going to give a few of them a try and I’ll let you know how it works out.

-- -- --

Have your say...

You must be signed in to reply.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics