Best way to cut 1-1/4" holes?

[Duct_Taper]

I want to start the main part of the work on my crossmember/skidplate for my YJ tonight, and the first thing I need to do is cut 6x 1-1/4" holes through 1/4" steel angle, to set up the attachment points at the frame. I have drill bits up to 1" (I think) but not bigger... I figured a hole saw would probably be the way to go, but it looks like I'd have to go pretty far out of my way to find one that will cut through steel well enough, and spend upwards of $40 to get it. Don't really want to...

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[BillaVista]

You should be able to find a qualit bi-metal hole saw for ~$20.

The Rigid ones from Home Depot are ok, as are the Milwaukee (red). Lennox or Blue-mol are even better but might be harder to find, depends where you are located.

Go slowly and use plenty of lube.

Drilling with a 1" bit and opening with a die grinder will work, but likely a lot more work, less visually appealing results, and depending on if you;re using a carbide bit or abrasive bit in the die grinder may cost you > $20 in consumables anyway.

I'd go with the hole saw.

 

[Duct_Taper]

Thanks for the advice. I'm in the west end... work in Kanata, live in Stittsville.

I guess I'll have a look at Home Depot on my way home.

 

[Kunker]

From Bill's last thread on hole saws:

http://ovo.ca/forums/showthread.php?t=1018

Should give you some ideas on where to pick up one of the better brands.

 

[Duct_Taper]

Yeah, I was reading that one, but I was hoping to avoid going in towards Merivale. Home Depot in Kanata is kind of sort of on my way home, so I'll check and see if I can get a decent one there.

 

[Duct_Taper]

Well, I ended up buying a Ridgid one from Home Depot... and maybe buying the 2 piece one was a mistake, but it was garbage. The arbor wasn't straight, so the hole saw just wobbled all over the place.

Was hoping to get a Milwaukee one there, but the only bi-metal ones they had were Ridgid.

Going to return it tomorrow morning... trying to decide if I should try the Bosch ones from CT or go out of my way and get a good brand from somewhere further away. Or maybe just get a 1-piece one? Suggestions?

 

[Duct_Taper]

Update:

Bought the Bosch one from CT, and they actually ended up being cheaper than the one I got from Home Depot. Worked like a charm, plus they have a sweet quick change mandrel.