A Lenox hole saw can cut perfect circles in a variety of materials, in a short amount of time. The tool consists of an arbor; which consists of a shaft that the drill chuck grips onto, a pilot drill bit (usually ¼" diameter), and threads to accept a variety of hole saws. The hole saws can be found in diameters from ¾" to four inches. Larger size hole saws can usually be ordered or found online. Hole saws as large as 6 7/8" are available, designed for recessed lighting cutouts in ceiling tile.
Things You'll Need
Lenox hole saw arbor
Attach arbor to your drill. Be sure the chuck teeth engage the 'flats' of the chuck properly.
Spin your hole saw onto the threads of the arbor. When it reaches the end, turn the hole saw back, if necessary, for the lock ring dogs to engage the two mating holes on the hole saw. Push the lock ring in to prevent the hole saw from spinning.
Don your safety goggles. Hold your drill perpendicular to the work surface. Line up the pilot drill with the center of your desired hole. Operate the drill at a relatively slow speed at first.
As the hole saw portion begins to touch the work surface, maintain control over the drill. The teeth should contact the work surface evenly to avoid chatter.
Once the hole saw has cut the initial circle into the work surface, you can increase drill speed as desired. When cutting ¾" or thicker wood, pull the hole saw away from the work occasionally to clear the cuttings from the hole.
Reduce drill speed as you near the end of the cut. When the drill breaks through the other side of the work surface, keep it running as you pull it back out.
Remove the plug cut-out from the hole saw: pull the lock ring back, turn the hole saw counterclockwise off the arbor. Use a punch or screwdriver to push the plug out.
It’s difficult to drill a larger hole after you have already used a smaller hole saw, as the pilot drill needs to grip material to maintain center. Choose the correct diameter hole saw initially, or expect to enlarge your hole by other means such as a file or grinding stones.
Always follow the precautions of your drill’s operating manual.