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One Great Tip » Workaround: Make Any Size Hole
Workaround: Make Any Size Hole
Article By Dave Munkittrick
Photos By author
Posted: Jan 6, 2012
I know circle cutters aren't a lot of money. But the thought of a steel arm swinging around at face level with a knife makes me nervous. Besides, that single blade tends to tear up the grain around the hole.
Buying a dedicated hole saw for every size you may need is an expensive proposition. Instead, I grab a spade bit, my rabbeting bit, bearings and a pattern cutting bit to make just about any size hole I want.
Here's how it's done:
I know circle cutters aren't a lot of money. But the thought of a steel arm swinging around at face level with a knife makes me nervous. Besides, that single blade tends to tear up the grain around the hole.
Buying a dedicated hole saw for every size you may need is an expensive proposition. Instead, I grab a spade bit, my rabbeting bit, bearings and a pattern cutting bit to make just about any size hole I want.
Here's how it's done:
Drill A Large Hole  First punch a hole large enough for your rabbeting bit to easily fit through. |
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Cut The First Rabbet
Rout the first rabbet using the edge of the hole as a guide. You'll use the different sized bearings to adjust the size of your hole on the last cut. In the meantime, to enlarge this hole as fast as possible I fit the router bit with the smallest bearing to produce the largest rabbet. |
| Cut The Second Rabbet  Flip the board over and cut the second rabbet. Using the edge of the first rabbet as a guide. |
| Cut The Third Rabbet
Get the idea? Keep flipping and cutting until you get close to the desired hole size. Measure what you need to complete the hole and fit your rabbeting bit with the appropriate sized bearing. |
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Make The Final Cut
Make the final cut with a pattern cutting router bit. There you have it; a big and easy hole.
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9 Comments
Great idea. Where can I find different size bearings for my rabbeting bit?
Dave, Thank you for this posting. It is one of the most valuable procedures I have read in 3 years.
Great technique, I will certainly use it.
I think I have a great idea that I have not seen displayed for slicing small logs (10-12 inches). If you are interested I would be pleased to share my idea. Stuart
Stuart- You can send your tips to editor@wwgoa.com G
Hi I currently get the WWGOA DVD's and I have purchased all but one so far. I'm interested in registering for the website, but I just wanted to be sure I won't start getting duplicate DVD's. Thanks, Jim Turcott
Very ingenious!
Nice alternative to router on a swing arm with nail/pin pivot point for a one off hole! I'm sure you would agree that the number of steps that you do this would add up the inacreacies in the final hole, but not all one off holes need to be that acreate do they.
Rockler woodworking! www.rockler.com carries them. You can buy a set with several diameters with or without their rabbeting bit Glad you liked the tip!