Replies

1. 
   Samson | Nov 21, 2009 07:53pm | #1

   That's a big hole to try to drill cleanly by any method using a drill.  I would suggest routing out the waste with router using a template or cutting out most of the waste with a jigsaw and then using a router to clean up and perfect the edges.

1. 
   benchbolt | Nov 21, 2009 08:30pm | #2

   Good idea, saves some $ on a not often used bit.  I'm wondering if a template of the finished part would be the better way, rather than drilling, then cutting in two.

2. 
   KeithNewton | Nov 22, 2009 03:58am | #3

   Mark, I don't know why Lenox and others who make hole saws use so many teeth, and grind the teeth the way they do. When I get a new one, I put a narrow wheel on a grinder, and grind away at least two of every three teeth, leaving a deeper gullet which allows longer cutting before they are full. I also touch the face of the ones that I leave, so there is no hook angle, which eliminates the snag that will break your arms with a powerful drill.

   On a drill that large, I might grind off 4 of every 5, or even more. This will allow you to drill longer and a lot faster. However, the cut is really not very smooth with any hole saw, so you might just want to use it to make a template that you use to guide a router for the finish cut if you have a lot to do.

1. 
   benchbolt | Nov 22, 2009 04:53pm | #6

   Thanks Keith, I think the template and router idea will provide for a more consistent and cleaner part.

3. 
   JeffHeath | Nov 22, 2009 04:47am | #4

   I have made a few wine racks in my day, and have used the same cradle style to hold bottles as I believe you are suggesting. I've always used a 3 1/4" forstner bit that is very sharp in my drill press. I've had no problems. I keep the shop vac at hand, literally, to avoid the potential mess of shavings.

   Jeff

1. 
   benchbolt | Nov 22, 2009 04:55pm | #7

   Thanks Jeff, What brand of bit do you use in that size?

1. 
   JeffHeath | Nov 22, 2009 07:12pm | #9

   I have no idea. I'm not a brand guy. It was hss, and I sharpened it before using it. Not hard to do, and takes, maybe, 10 to 15 minutes and it's ready to go. I think I bought it at Rockler, but it was a while ago.Jeff

1. 
   benchbolt | Nov 22, 2009 09:51pm | #10

   Thanks again Jeff,

   Pardon my inexperience, but could you share some techniques or tips for sharpening a forstner bit. It's one of many things I have never attempted...

   Mark

1. 
   JeffHeath | Nov 23, 2009 05:31pm | #12

   Using slipstones and diamond hones, I sharpen the bevels of the forstner bit as you would a chisel. Sharpening is simply the polishing of two intersection metal surfaces to the same degree. By removing the rough imperfections in the intersecting edge, you sharpen the tool. Make sure you pay attention to the perimeter of the bit, as well.Jeff

4. 
   hammer1 | Nov 22, 2009 07:19am | #5

   You can chuck a sanding drum in the drill press and smooth up the cuts. Spraying a little silicone on the hole saw or bit will reduce friction and heat. Backing out and clearing dust also helps a lot. Speed of the saw and feed speed also play a part in getting the optimum cut.

   Beat it to fit / Paint it to match

5. 
   oldusty | Nov 22, 2009 06:18pm | #8

     I use a circle cutter or fly cutter , they are adjustable and one shot will do it as any proper drill bit will .

    Also they do make carbide tipped hole saws made for drilling wire grommets into countertops.

       you could bandsaw them out then sand with drum sander .

         regards dusty

6. 
   joinerswork | Nov 22, 2009 10:09pm | #11

   Bench, and all,

   Huh, I believe I'd start with two narrow boards, tack 'em together, lay out the cuts and bandsaw/ jigsaw them out.  Then clean up with a sanding drum.

   Maybe that's why us left handers have the reputation of doing everything backwards?

   Ray

1. 
   oldusty | Nov 23, 2009 06:09pm | #13

     Ray , I'm not a lefty but perhaps should have been as I too do most things backards .

              dusty

2. 
   RalphBarker | Nov 23, 2009 08:10pm | #14

   That's the easy way, certainly . . . if your bandsaw is large enough for the length of the boards. If not, one could do partial rough cuts to the open side of the bandsaw, flip and finish the cut from the other direction.

7. 
   knuts | Nov 24, 2009 04:19pm | #15

   I like routers for bigger holes and Eagle and probably others, sell a hole cutting template for routers, the largest hole is 3 1/2.