Choosing a hole saw: which type and size for wood, metal and tile?

Short answer: choose a hole saw first by material and then by size. A bi-metal hole saw is the all-rounder for wood, sheet material, plastic and thin metal. A hole saw with carbide teeth works faster in wood, plasterboard and plastic and can also cut soft masonry. For tile, glass and natural stone you use a diamond hole saw, and for concrete and masonry a core bit. Always drill at low speed and switch off the hammer setting, except with a core bit that is specifically made for it.

👷 If it involves a hole in a load-bearing structure, a large hole in concrete or a feed-through for gas, water or electrics, leave it to a professional. Calling in a professional is never unnecessary: they know where you may and may not drill and have the heavy equipment for large diameters.

Which type of hole saw for which material?

• Wood, plywood, MDF, plasterboard and plastic: bi-metal, such as a 35 mm bi-metal hole saw or 68 mm bi-metal hole saw, or a 68 mm multi core bit with carbide teeth with carbide teeth. The latter also stays sharp in chipboard and soft masonry.
• Steel, aluminium and stainless steel: bi-metal with fine teeth, low speed and cutting oil or water for cooling.
• Tile, porcelain, glass and natural stone: diamond. For the drill you use the 60 mm diamond hole saw for drills; for the angle grinder there is the 60 mm diamond hole saw with M14 for angle grinders. For small holes in tile a 8 mm diamond drill bit is handier. Also read our blog on diamond drilling in tile and concrete.
• Brick, sand-lime brick and concrete: a 68 mm core bit for masonry and concrete on a suitable drill.

Which size do you need?

The diameter is always printed on the hole saw. A few common sizes:

• 20 to 25 mm for cable and pipe feed-throughs, for example with a 20 mm bi-metal hole saw.
• 35 mm for hinge cups in kitchen cabinet doors and small feed-throughs.
• 68 mm for back boxes and downlights in plasterboard or wood.
• 102 mm for ventilation and drainage, with a 102 mm bi-metal hole saw.

If you often drill different sizes, a bi-metal hole saw set for installers (20 to 68 mm) or a diamond hole saw set is more practical than separate saws.

⚠️ Check beforehand with a multifunction wall detector that no pipes or cables run behind the wall or in the floor. Leave work on the electrical installation, such as connecting a back box, to a certified electrician.

How to drill a clean hole

1. Clamp the workpiece with a automatic quick-release clamp or in the vice. A hole saw that jams will spin the workpiece or your wrist.
2. Choose a low speed. The larger the diameter, the lower the speed. A large hole saw in metal turns much slower than a small one in wood. Follow the values on the packaging or product page.
3. Switch off the hammer setting for bi-metal, carbide and diamond. Use a cordless drill driver with a sturdy side handle. Read more about cordless tools in our blog on the Stalco 20V battery system.
4. Start with the pilot drill and only set the hole saw down squarely once it has gripped. Keep the machine square to the work. For many identical holes a pillar drill is ideal.
5. Cool and clear. Use cutting oil for metal, water or a wet sponge for tile and glass. Pull the saw back regularly to clear the chips.
6. Drill from both sides in thick wood: drill until the pilot drill comes through on the other side and finish the hole from that side. This prevents tear-out.

💡 Mind the maximum cutting depth of the hole saw. If the workpiece is thicker, drill in stages and remove the core in between. A clogged hole saw gets hot and blunt.

Common mistakes

• Speed too high: the teeth turn blue and blunt. Especially in metal and stainless steel.
• Hammer setting on: teeth break off and tiles crack.
• Drilling tile or glass dry with a diamond hole saw that is meant for wet use.
• No firm clamping: the workpiece breaks loose and spins.

Working safely

Always wear safety goggles: chips, tile shards and metal swarf fly in all directions. Use work gloves with nitrile coating when removing the core and touching the saw, as it is hot and razor-sharp after drilling. With a rotating machine, never wear loose gloves near the chuck, no loose sleeves and no loose hair. Vacuum dust from tile and stone with a construction vacuum cleaner.

Can I use a wood hole saw for metal?

A bi-metal hole saw can do both. A hole saw intended only for wood will be blunt within a few holes in metal.

Why does my hole saw keep jamming?

Usually because of too high a speed, too much pressure or a clogged saw. Lower the speed, pull the saw back regularly and clamp the workpiece firmly.

How do I get the core out of the hole saw?

Disconnect the machine from the mains or remove the battery and push the core out through the slots in the saw wall with a screwdriver.

The right hole saw makes the difference between a clean hole and a split workpiece. Choose by material and size, drill calmly and leave heavy or risky drilling to the professional.

Read also: Diamond drilling in tile and concrete · Carpenter's clamps: opening and clamping force · The Stalco 20V battery system

Where can you find everything for this job?

At Saniso, the online store for DIYers and professionals, you will find tools, materials and personal protective equipment for your job.

• Browse our construction tools and our workwear and safety.
• Create a customer account and order easily.
• Working on a bigger project or want to hand over the job? Request a project quote.
• Book a showroom visit, at least 24 hours in advance.
• Not sure which material suits your job? Get in touch with us.

In doubt about the approach? Feel free to call in a professional.

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