If you’re going to work with aluminum, you know that nothing works better than hole saws and drill bits. But not all of them are created equal, which can mean the difference between success and failure in your project.
Before you start drilling your metal, take a look at these five best hole saws for aluminum, each with its own unique features and benefits to consider.
Make sure you get one that will do the job properly.
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ToggleHow do I choose a hole saw?
There are a few things to consider when choosing a hole saw, such as the size of the saw, the type of teeth, and the type of shank.
- The size of the pilot bit determines the size of the hole saw. The pilot bit is the small drill bit in the center of the hole saw that helps guide it as it cuts.
- The type of teeth on the hole saw will also affect its performance. Spiral or worm gears should be used for softer materials like wood, plastic, rubber, or foam. Spun carbide will work better with harder materials like metal and concrete.
- Lastly, there are two types of shanks: keyless and keyed. Keyless hole saws can be adjusted at any time, whereas keys can only be adjusted once they have been assembled to their shafts.
- The final consideration is price; some models may cost more but will save you money in the long run because they require fewer replacement parts.
3 Best Hole Saws for Aluminum in the Market
1. Craftsman Hole Saw Kit
Some hole saw sets are very expensive, often including far more incremental sizes than most users would need. If you’d like to save a bit of money and get a quality set of hole saws without any extra accessories or uncommon sizes, we think the CRAFTSMAN Bi-Metal Hole Saw Kit is the best hole saw kit for metal and wood for the money.
This kit includes six sizes of hole saw, spanning from one inch to 2½ inches. One mandrel is included with an adapter so it will fit the larger hole saws. There’s no case and you won’t get any extra arbors or pilot bits. But because these things are left out, the CRAFTSMAN seven-piece hole saw kit is much cheaper than the kits from competitors.
Overall, these hole saws were solid performers. They had sharp teeth that bit well into both metal and wood and they didn’t dull quickly. We did have a bit of trouble with the collar getting stuck on the hole saws after use. It became very difficult to loosen again, but we got it with a little help from an adjustable wrench.
Pros
- High-quality bits for an affordable price
- Cheaper than other similar products
- Sharp teeth bite well
- Don’t dull quickly
Cons
- No Case
2. Bosch Master Bi-Metal Hole Saw Kit
The Bosch 25-Piece Master Bi-Metal Hole Saw Kit looks excellent on paper but doesn’t make par when it’s game time. Still, you get a lot with this kit, even if it is a rather large investment. Eleven hole saws are included, starting at ⅞ inches with the largest topping out at just three inches in diameter. You’ll also get a mandrel and pilot bit with several adapters, plus, a hard plastic case to neatly carry it all.
The main feature of this kit is the quick-change bit system that allows you to quickly and easily swap between different sized hole saws. While it does work for quick swaps between sizes, it also introduces a new problem.
The connection from the quick-change mandrel to the hole saw isn’t very secure. When it spins, there’s a lot of wobbles, which is particularly noticeable with larger hole saws and at higher speeds. This leads to broken pilot bits and holes that look ragged and awful instead of clean and neat like we’d all prefer. Though Bosch is a well-respected manufacturer of high-quality tools, we believe they fell short with this poorly-executed product.
Pros
- 25 pieces will cover most uses
- Quick-change bit system
Cons
- Doesn’t have a large option
3. Milwaukee Hole Saw Kit
If you are a frequent hole saw user and you know that you often need irregular sizes, then the Milwaukee All Purpose Professional Hole Saw Kit has 22 hole saws of different sizes, comprising a 28-piece set in total, with sizes ranging from ¾” to 4¾ inches. To keep it all organized, you’ll get a hard plastic carrying case with room to add more hole saws in the future, in case you still need to expand. Also included are three arbors and three pilot bits.
But these aren’t just any old hole saws. These are ice-hardened with Matrix II bi-metal teeth for a longer lifespan and better durability than other hole saws on the market. This means that they’ve undergone a cryogenic hardening process that results in a lifespan that’s up to 50% longer.
The teeth on these hole saws are very sharp, and they seemed to cut through the material quicker than other hole saws we tested. Moreover, they stayed sharp much longer, retaining their cutting power and speed for many holes, past the point when others would start to slow down and the teeth would show visible wear.
Pros
- Ice-hardened for a lifespan that’s up to 50% longer
- Large 28-piece kit covers all the bases
- Spans from ¾” to 4¾”
- Three arbors included
Cons
- On the expensive side
What’s the Largest Size Hole You Need?
The first thing to ask yourself is; what size hole do you need? If you’re drilling a hole for a specific purpose, this shouldn’t be too difficult of a question to answer. But if you’re just getting it to have for the next time you need to make a perfectly round hole, then it might be more difficult.
When using your hole saw kit to make holes for plumbing, a common use, you’ll rarely need any hole saws over 2½ inches since most household plumbing is smaller than this. For this reason, the largest bit in most hole saw kits is 2½ inches.
But if you have a specialty use that requires a hole that’s larger than this, you’ll need to choose a kit that has hole saws large enough to accommodate your needs. If the kit won’t make a hole big enough for your purposes, then it won’t do you much good.
Try to determine the largest hole you might need to make, and choose a hole saw kit that has bits at least that large.
How Often Do You Drill Large Holes?
After determining what the largest size hole is that you might need to drill, it’s time to think about how often you’ll really use this tool. If your hole saw kit is only going to see occasional use, being broken out only sparingly for a solitary hole here or there, then you’ll be fine with lower quality and less expensive hole saw kit. These hole saws might wear out quicker than a better set, but with occasional use, they’ll still last a very long time.
On the other hand, if you use hole saws on a regular basis, it would be a wiser investment to get a more professional-quality set that won’t dull quickly. If you’ll be using them a lot, then you’ll benefit more from the improved lifespan.
Does it Matter What Material the Hole Saw is Made Of?
One of the most important features of a hole saw is the material from which it is made. Which material you’re going to need is largely dependent on what you’re going to be cutting. Steel hole saws are generally best for drilling wood, fiberglass, PVC, and aluminum. Cobalt hole saws, known for their ability to dissipate heat quickly, are designed to work with aluminum and harder metals like stainless steel.
You probably won’t find many black oxide-coated or titanium-coated steel hole saws, but if you do, they work with hard and softwoods, many metals, PVC, and fiberglass. There are also carbide-tipped hole saws, which stay sharp the longest, but also work the best when drilling tile and masonry. If you’re working with something much harder than that, you may need to invest in diamond-edge, which will last longer and cut faster in the same tasks relative to a carbide-tipped model.
Frequently Asked Questions
Can you use a hole saw on aluminum?
You bet you can. A hole saw is a versatile tool that can be used on a variety of materials, including aluminum. In fact, hole saws are often the best choice for making clean, precise cuts in aluminum.
How do you cut a hole in aluminum?
You can use a variety of tools to cut a hole in aluminum, but the best tool for the job is a hole saw. Hole saws are designed specifically for cutting through metal and come in various sizes to accommodate different thicknesses of aluminum. To cut a hole in aluminum, follow these steps-
- Select the appropriate-sized hole saw that will work with your project specifications.
- Drill a pilot hole in one end of your aluminum bar with an appropriately sized drill bit. Take care not to hit any obstacles as you drill.
- Insert the tip of the hole saw into the pilot hole and start drilling until you feel resistance on the other side of your material. Make sure to hold the drill straight while you’re cutting.
- Continue drilling around the circumference of your circle until it’s complete.
How do you cut a 6-inch hole in aluminum?
A hole saw is the best way to cut a 6-inch hole in aluminum. In order to cut a 6-inch hole, follow these steps-
- Drill a pilot hole into the center of the circle where you want your cut to be, then widen it with a drill bit that’s at least as big as your diameter measurement.
- Place the tip of your hole saw against the edge of this drilled opening and slowly push it down until you’ve reached the depth required.
- Continue cutting until you reach your desired size and pull out from inside when finished.
Can a hole saw be used on metal?
The answer is yes, but it’s important to choose the right type of hole saw for the job. There are several factors to consider when choosing a hole saw, such as the material you’re cutting, the thickness of the material, and the type of teeth on the blade.
Conclusion
They say that half the job is having the right tool. Well, if that job is drilling holes, then a hole saw kit is certainly the right tool. We drill a lot of holes, so we wanted to find the hole saw kit that could handle the hardest drilling through a variety of materials without getting worn down after just a few rounds. Though our reviews compared five of these kits, only three have earned our recommendations.