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.

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.

Make The Final Cut     Make the final cut with a pattern cutting router bit. There you have it; a big and easy hole.