Best Holesaw for Notching Tubing

best hole saw for notching tubing
Photo courtesy Iwao via flickr. Used under a CC BY 2.0 license.

Working with metal can be a difficult and time-consuming process, but with the best hole saw for notching tubing, it can be much more efficient when building a roll cage.

Hole saws come in various different types, each with its own advantages and disadvantages. In this article, we’ll discuss the different types of hole saws, their benefits, and how to choose the best one for notching tubing.

Top rated holesaws on Amazon

BOSCH HDG11 11-Piece Diamond Hole Saw Assorted Set for Hard Materials for Use Only with Machines Designed for Wet Sawing and on GFCI-Protected Circuit
  • Vacuum-brazed diamond grit cuts faster and lasts longer
  • Segmented teeth reduce debris and heat
  • AutoStart pilot bit is spring-loaded, retractable shaft allows walk-free cutting without a pilot hole
  • Pilot bit offers unique grind that starts holes accurately every time
  • Plastic case

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Milwaukee 49-56-9290 10 PC BIG HAWG Hole Saw w/Carbide Teeth Kit New
  • Mfr: Milwaukee
  • UPC: 045242500758
  • Type: Hole Saw, Kit

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DEWALT Hole Saw Kit, 14-Piece, Includes 2 Quick Change Mandrels and Pilot Point Bits (D180005)
  • Door lock hole saw kit utilizes C-clamp design with tool-free clamping and no surface damage
  • Door lock kit utilizes alignment window and taller bushings to deliver accurate height placement and straight drilling with the hole saw set
  • Door lock kit includes two adjustable bushings which accept both standard backsets and both common door thicknesses

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Factors to Consider When Choosing a Hole Saw

When you need to cut a notched hole in a pipe or tubing, a hole saw is the ideal tool for the job. But not all hole saws are created equal, and there are some important factors to consider when choosing a hole saw that will fit your needs.

In this article, we’ll go over some of the key features to look out for when shopping for a hole saw.


When choosing a hole saw, it is important to consider the material it is made out of, as this will determine what type of metal and other materials can be cut. There are three main types of material found in a hole saw: carbon steel, bi-metal, and carbide-tipped.

Carbon steel: Carbon steel hole saws are the most economical option and are best for cutting soft metals such as aluminum or tube notching. This type of hole saw often has an outside coating of black oxide on the teeth to reduce heat from prolonged cutting and make the teeth more durable while cutting.

Bi-metal: Bi-metal hole saws are more durable than carbon steel and are capable of cutting harder metals such as stainless steel. This type of hole saw is made up of two layers; one layer that is high speed steel which retains its shape in high heat applications and a second softer layer that provides strength and durability to keep its shape when used repeatedly.

Carbide-tipped: Carbide-tipped hole saws provide the highest accuracy when cutting hard materials such as cast iron, brass or glass fiber reinforced plastic (GRP). They have tungsten carbide tips which provide superior abrasion resistance allowing for clean cuts when drilling hard materials with little effort or force needed from the user.


Size is an important factor to consider when choosing a hole saw for notching tubing, as the size will affect the overall performance of the saw itself, as well as the final product. Hole saws that are too small will have difficulty creating clean cuts and may leave bits of material behind that may impair the strength of whatever object is being cut. On the other hand, hole saws that are too large can be challenging to control and they may cause vibrations that reduce accuracy and precision.

It is important to select a hole saw size that is appropriate for your project so that you can get high-quality results with minimal effort. Additionally, hole saws come in a variety of diameters that you can choose from depending on your specific needs; some sizes are ideal for cutting through softer materials such as plastic or wood while larger sizes are more suited for metal materials like stainless steel or aluminum. Make sure to evaluate your project’s requirements before selecting a size so you can get optimal results with minimal effort.


When choosing a hole saw, the configuration of the cutting teeth must be considered. The higher the number of teeth, the finer and slower the cut — which is often better when used with softer materials. Borehole saws may have between 6 and 44 teeth, depending on their size and purpose.

The tooth pattern should also be matched to the material that needs to be cut; there are different types of teeth suitable for different types of metals. Some borehole saws are designed specifically for metal cutting and will have teeth designed for fast penetration with minimal vibrations or load on the drill motor. Hole saws designed for general purpose cutting applications will usually include a mixture of standard (flat-topped) and ‘V’ shaped or profiled teeth that are suitable for a wide range of materials including plastics, wood and composites, as well as metal.

It is also important to consider how the hole saw will be used in order to choose one with appropriate heat resistance qualities; some hole saws are designed to resist high temperatures better than others. This can be important if high speed drilling is required or if it is likely that sparks may occur during drilling, as this can often cause heat build-up at specific points on the saw blade.

Pilot Drill

When selecting a hole saw, one of the most important factors to consider is the size and type of pilot drill used with each saw. The pilot drill provides stability and accuracy when drilling into metal and other hard surfaces. Its job is to protect the teeth on the hole saw blade and guide it into the material. There are two types of pilot drills available: integral (attached) or separate (detachable).

The integral style has a solid steel body with a replaceable carbide tip designed to work with most types of substrates including metal, wood and plastic. This option offers greater precision due to its design, as well as superior protection from heat buildup caused by friction as it guides the hole saw through material.

The separate type has an interchangeable shaft design which allows for flexibility when cutting into multiple materials, such as soft-wood thinwalled PVC pipe or thin-walled steel tubing. Although not as precise as an integral type pilot drill bit, it does allow for quick changing between one size hole saw to another without having to purchase whole new sets for each size tool.

Whether you’re looking for accuracy or flexibility, make sure you choose the right type of pilot drill for your application in order to get maximum efficiency from your Hole Saw tool in notching tubing or other metal products.


When selecting a hole saw, the shank is an important factor to consider. Hole saws with an integral shank are designed for use with drills that do not accept screwdriver bits, commonly in ranges from 1/4-inch to 1/2-inch. These hole saws are compatible with only drill chucks and can often be used in hammer mode when drilling hard materials. A pilot drill bit comes integrated into the hole saw itself, which assists the user in cutting straighter holes and starting from the center of their material.

Winged or “knockout” style hole saws have a round backplate that supports the cutting edges of the saw and a screw thread that allows it to be attached to drills with suitable keyless chucks. Multiple nut sizes on the backplates allow them to fit in most modern impact drivers as well.

It is important to use correct power tools while using this type of hole saw since improper torque can cause shanks to break or heat up excessively – damaging your workpiece as well as your tools. Tungsten carbide or high-speed steel variants of these shanks are available depending on usage requirements such as drilling through tougher materials like steel or concrete blocks.

Best Hole Saw for Notching Tubing

Bestseller No. 1
EZARC Carbide Hole Saw Kit, 3 Piece Carbide Tipped Hole Cutter with Pilot Drill bit for Hard Metal, Stainless Steel, Iron, Aluminum, Alloy
  • Industrial grade metal drilling hole cutter, more than 10 times longer life than Bi-Metal hole saw on hardened metal drilling
  • Extremely long lifetime and no teeth breakage for any tough job with high-end tungsten carbide technology
  • Provide fast and precise cuts into stainless steel, sheet metal, cast iron, mild steel, aluminum and FRP smaller than 5mm
  • Smooth cut with perfect cutting quality for every hole
  • This hole saw set includes 3 pieces hole cutters with dimensions of 7/8 inch, 1-1/8 inch, 1-3/8 inch, 2 pieces HSS pilot drill bits and 1 piece hex key
Bestseller No. 2
Klein Tools 31872 Heavy Duty Hole Saw Kit, Includes Carbide Hole Cutters and Pilot Bit in Rust-Proof Molded Plastic Case, 4-Piece
  • Heavy duty, durable carbide hole cutters for long life
  • Hole Cutters cut quick precise holes in stainless steel, mild steel, iron, copper and brass sheet up to 3/16-Inch (0.5 cm) thick
  • Split point pilot drill bit prevents bit walking
  • Set contains: 7/8-Inch, 1-1/8-Inch, 1-3/8-Inch plus one extra pilot bit
  • Integrated flange prevents the operator from drilling beyond the sheet metal
SaleBestseller No. 3
Ideal Electrical 36-311 TKO 4 Pcs Hole Cutter Kit Carbide Hole Cutter Set, Smooth Start Pilot Bit, Carry Case
  • Superior Performance: TKO carbide tipped hole cutters provide the most precise and clean hole saw and knockout replacement in the industry with increased durability and long life in sheet metal or stainless steel
  • Precise Design: The hole saw cutter has ground carbide teeth made from high quality HSS producing clean, burr-free holes. The carbide cutter includes a built-in flange to prevent overdrilling
  • Smooth Cutting: The innovative design includes a SmoothStart pilot drill which guides the cutter to the surface, avoiding damage to the cutter and ensuring smoothly cut holes with minimal walking
  • Convenient Usage: The carbide tipped cutting hole saw has an integrated arbor for solid rotation providing smooth accurate holes without chattering. The ejection spring effortlessly ejects the slug
  • Product Specifications: The TKO carbide tipped hole cutter kit is supplied with SmoothStart replacement tip, 7/8 in., 1 1/8 in. and 1 3/8 in. diameter hole cutters, 3/8 in. shank and carrying case. The carbide tip can cut up to 1/8 in. thick steel
Bestseller No. 4
Carbide Hole Cutter 7/8, 1-1/8, 1-3/8”, Heavy Duty Carbide Tipped Hole Cutter for The Professional, Carbide Hole Saw Kit with 3 Extra Pilot Bits by S&F STEAD & FAST
  • Heavy duty kit of carbide hole cutter with integrated pilot bit and sharp TCT blades; cutting diameter of 7/8 , 1-1/8, 1-3/8 inch, carbide hole cutter kit includes 3 extra pilot bits, 1 hex wrench
  • Made of industrial grade premium materials for extra long life; all pilot drill bits are made of M35 HSS steel to ensure they do not break easily and include an ejector spring for easy slug ejection
  • Compatible with hand drills (cordless and corded), impact drills, low speed / spade handle drills and platform / press drills
  • Use to cut perfect smooth holes in sheet metal of thickness < 3/16” (5mm); stainless steel hole saw also suitable for other materials such as aluminum, stainless steel, brass, tin, cast iron, plastic...
  • Packaged in an attractive rust-proof aluminum case so you can store them neatly and securely; perfect in any electrician’s tool kit
SaleBestseller No. 5
Vearter 15PCS TCT Hole Saw Kit, 5/8'' to 3'' Carbide Bit Set with Pilot Drill, Holesaw for Hard Metal, Stainless Steel, Iron, Mild Steel, Aluminium, Alloy, Plastic, Fiberglass(Black Box)
  • Kit Includes - 15 Hole drills in sizes 5/8''(16mm), 3/4''(19mm), 7/8''(22mm), 1''(25.5mm), 1-1/8''(29mm), 1-1/4''(32mm), 1-3/8''(35mm), 1-1/2''(38mm), 1-5/8''(41mm), 1-3/4''(45mm), 1-7/8''(48mm), 2''(51mm), 2-1/4''(57mm), 2-1/2''(64mm), 3''(76mm), 2 hex spanners, all stored securely in a sturdy aluminum case.
  • High-Quality Material - Made of industrial-grade carbide tipped with a high-grade titanium-coated pilot bit, this hole cutter is built to last. It is rust-resistant, durable, and sturdy, ensuring long-term performance.
  • Exceptional Cutting Properties - Designed to provide exceptional cutting performance, with its sharp edge, low consumption, impact resistance, and wear resistance. It delivers smooth and perfect cuts for every hole.
  • Versatile Drilling Capabilities - This hole cutter is a versatile tool that can be used for drilling various materials, including stainless steel plates, hard metals, iron, mild steel, alloy steel, aluminum, fiberglass, and plastics. It is not recommended for drilling tiles, glass, concrete, and stone.
  • Wide Compatibility - Compatible with hand-held drills, bracket motor-driven drills, and mobile strip magnetic drills. It is widely used in heavy industrial plants, such as heating, ventilation, and air conditioning applications, where precision cutting in high-quality stainless.
Bestseller No. 6
HIGHFIRE 20pcs Carbide Hole Saw Kit with Case, Carbide Tipped Hole Cutter with Pilot Drill bit for Stainless Steel, Iron, Aluminum, Alloy, Plastic
  • 【TCT Hole Saw Set】13pcs hole saw kit which cutting diameter 64mm(2-1/2"),90mm(3-9/16"),16mm(5/8"),19mm(3/4"),22mm(7/8"),25mm(1"),29mm(1-1/8"),32mm(1-1/4"),35mm(1-3/8"),38mm(1-1/2"),44mm(1-3/4"),51mm(2"),54mm(2-1/8"), 2pcs drill bits ,2pcs hex keys and 3pcs springs
  • 【Unique TCT Hole Saw】highfire TCT hole saw teeth designed with three-blade, includes outer blade, middle blade, and inner blade, making it sharper and more efficient, ideal for cutting hard metals;
  • 【Wide Application】Ideal for stainless steel, metal, iron, and plastic, aluminum, FRP, etc. so on. Remember to add coolant during continuous high-speed drilling.
  • 【Efficient Cooling】Designed with double round circles to remove metal filings easily and efficient cooling.You can use a lubricant ,so the bit will not overheat. It can be water or oil.
  • 【24-Hour After-Sales Service】If you have any questions about the product, please contact us in time. We will reply to you within 24 hours.
Bestseller No. 7
dashap 5PCS Hole Saw Kit with Case, Carbide Hole Cutter Set for Metal, TCT Hole Saw Set for Hard Metal Plastic and Wood, Within 7/8" to 1-3/8" Cutting Diameter
  • ????Everything you need in one neat set: 5PCS item in a red quality carrying box, 3 hole saws with separate drill bits, 2 additional drill bits, and 1 hex keys equipped with 1/4'' shank. This is an excellent set for your heavy-duty hole cutting needs.The red box allows you to carry the hole opener more easily
  • ????Hole saw cutting diameter in 3 sizes: hole saws are marked metric, including 22mm(7/8"), 28mm(1-1/8"),35mm(1-3/8")fulfill your most basic requirements.
  • ????Our hole saw is capable of cutting holes in 3mm stainless steel, 15mm iron plate, 15mm aluminum alloy, metal tube, and other metal materials. Widely used for your benefit. Remember to apply oil or coolant while drilling at high speeds
  • ????The distinctive toothed blade allows for faster cutting, while the ejection spring allows for more precise hole cutting. The attached ejection spring eliminates the annoyance of manually removing slugs by mechanically ejecting the material.
  • ????Smoother cutting:Unique tipped tooth blade,faster cutting experience.Eligible for rechargeable drill,portable hand drill,bench drill,eletric drill and etc. For safety purposes,please wear protective goggles and gloves when using our hole saw set.
Bestseller No. 8
Milwaukee 49-56-9290 10 PC BIG HAWG Hole Saw w/Carbide Teeth Kit New
  • Mfr: Milwaukee
  • UPC: 045242500758
  • Type: Hole Saw, Kit
Bestseller No. 9
Anbull Carbide Hole Saws Hole Cutter Set 9 Piece Stainless Steel, Includes 6-Piece Hole Cutter 2-Piece Pilot Drill Bits 1-Piece L-Wrench and Molded Plastic Case, Long Life Hole Saw Kit for Hard Metal
  • High Quality: Adopt tungsten carbide material, unique cutting-edge grinding technology, sharp and wear-resistant, not easy to break, drilling high efficiency and fast chip removal, extremely long service life.
  • Fast Cutting & Chip Removal: Use high-strength, high-sharp tungsten carbide blades,and anti-vibration gear design, fast and durable. Arc-shaped chip pocket design, conducive to the smooth discharge of iron filings, reducing chip jamming, and conducive to chip holding at the limit cutting depth.
  • Precise Cutting: Stepped pilot drill bit design, precise center positioning, providing fast and precise incision, and with step cutting function, effectively decompose the cutting resistance of the centering drill, reduce the impact force at the moment of drilling through and avoid chipping of the cutting edge; And Pilot Drill Spring Design, control the displacement of the cutting edge, avoid damaging the drill bit by sudden cutting.
  • Scope of Application: Used with power drill, magnetic drills, benchtop drills to quickly and accurately cut stainless steel, sheet metal, cast iron, mild steel, aluminum and FRP less than 5 mm. Note: Prohibit the use of ceramic tile, concrete, walls, stone.
  • This Hole Saw Set Includes : 6 PCS hole cutters with dimensions 7/8 inch, 1-1/8 inch, 1-3/8 inch,1-3/4 inch, 2 inch, 2-1/2inch, 2 pcs pilot drill bits and 1 pc hex key. All are packed in a box, light and easy to carry.
Bestseller No. 10
DEWALT DWACM1802 Metal Cut Carbide Holesaw Set, 3 Piece
  • Metal hole saw has carbide teeth for long life in material
  • Hole saw kit has an ejection spring for easy plug ejection
  • Raised shoulder of the hole saw set helps prevent break through
  • Optimized tooth design for fast drilling speed
  • Optimized pilot bit for long life in metal

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When selecting the best hole saw for notching tubing, there are a few factors to consider. The size of the hole saw should be appropriate for the size and thickness of the tubing you are working with. The tip of the hole saw should be sharp and undamaged to ensure smooth cutting and prevent any jagged edges on your tubing. You also need to make sure that the hole saw will fit onto your drill or other power tool.

When drilling into metal, carbide tipped hole saws are recommended due to their superior strength and durability under pressure. Carbide tipped hole saws can also cut deeper than standard steel or high speed steel (HSS) blade options and may require less aggressive drilling techniques during operation.

Diamond tipped hole saws are ideal for cutting through hard materials like ceramics, stone or concrete and offer superior speed over carbide-tipped blades. These blades come in a variety of shapes, sizes, and quality combinations depending on your application needs but may require some extra care with rigorous cleaning after every use to avoid material build-up in on the blade’s tips which can greatly reduce accuracy and performance over time.

For softer materials such as wood, plastic or aluminum High Speed Steel (HSS) blades will offer an ample amount of strength while also being more economical than most alternatives. However, these blades do have a disadvantage in that they must be sharpened regularly due to their wear resistance being lower than other metals used in blade construction.

Lastly bimetal blades have been created specifically for notching tubing due their increased flexibility when performing intricate cuts which renders them perfect for producing deep grooves or slots into tubes without damaging other areas during operation. Bimetal holesaws often operate at faster speeds due to their permanent teeth configuration which maintains its sharpness for extended periods of time thus making it an excellent option for job sites that requires high speed drilling without sacrificing tool life or precision like critical medical equipment manufacturing processes where accuracy is paramount regardless of budget constraints.

Best Holesaw for Notching Tubing on the Market

When searching for the best hole saw for notching tubing, there are many factors to consider. The size and type of tubing to be cut will determine which hole saw is the most suitable for the job. Additionally, other factors such as hole saw material, type of cutting edge, and the application should be taken into account when making a selection.

By researching the product characteristics and comparing prices from multiple vendors, you can ensure that you find the best hole saw for your project needs.

Originally posted 2023-04-24 08:01:51.