The Best Hole Saw for Cutting Thick Metal (2021)

Last Updated On 14th Jul, 2021

As a plumber, carpenter, electrician, or DIYer, you’ll need to cut through thick metal sheets from time to time. Without the right tools, that task can become both difficult and frustrating, especially when you’re working on thick metals. 

That’s why you should consider buying the best hole saw for cutting thick metal! A hole saw kit contains cylindrical cups with serrated edges. Thus helping you to cut holes of various sizes in different materials.

The saw’s serrated edges cut through the material. The other end features a drill chuck/ arbor to drive the tool. 

best hole saw for cutting thick metal

Now that you understand the importance of hole saws, you should get one for immediate or future use! But, which is the best hole saw for metal to buy? 

Considering the assortment of cutting tools out there, you may end up with a cutter that doesn’t suit your needs. To help you avoid that, this article has the best tools for DIYers and professionals alike. 

Here they are! 

Image

Name

Editor's Rating

Price

LENOX Hole Saw Set

LENOX Hole Saw Set

5 out of 5

Milwaukee Hole Saw Kit 28 piece

Milwaukee Hole Saw Kit 28 piece

4.5 out of 5

HYCHIKA Hole Saw Set

HYCHIKA Hole Saw Set

4.5 out of 5

The Best Hole Saw for Cutting Thick Metal

1. LENOX Hole Saw Set (308042000G)

LENOX Tools Hole Saw Kit

When it comes to cutting tools and saw blades, LENOX TOOLs is among the most trusted brands out there. They have done everything to ensure that this 26-piece hole saw kit lives up to their reputation! 

To start with, these pieces feature innovative T3 technology. This increases their durability, making them last up to 1.5 times longer than the previous from LENOX.

So, for those looking for a set that guarantees extended durability, this kit is a great option! 

Even better, each unit is crafted from bi-metal material. They’ve enhanced tooth geometry, excellent coating, improved wall thickness, and thin kerf design. All these factors reduce tooth loss and extend the saw’s durability further! 

The increased wall thickness maximizes the strength of each saw. Thus helping you to cut through the strongest materials quickly. It’s also worth noting that these saws are 10% taller, giving you an effective cutting experience. 

Apart from cutting through metal, you can use this set on wood as well. The kit comes with 3 pilot drills, standard arbors, and hole saws of different sizes. 

On the downside, these tools have dull blades. So, avoid using them to cut through stainless steel. Also, the set comes at a premium price, but it’s worth it. 

With that in mind, these pieces come packed in a strong carrying case, separated into slots. This makes the pieces easy to store and transport.

Pros 

  • Highly durable set 
  • Larger & sharper teeth 
  • Contains different-sized cutting tools 
  • Heavy-duty construction 
  • Incredible cutter style 
  • Well-organized, strong carrying case

Cons 

  • Premium price 
  • Not ideal for cutting stainless steel

2. Milwaukee Hole Saw Kit 28 piece (49-22-4185)

best metal cutting holes saw

Milwaukee is another incredible brand based in the USA. And their all-purpose hole saw kit certainly deserves to be on our list. It’s arguably one of the best hole saw set for woodworkers, electricians, and plumbers. 

Consisting of 28 pieces, this kit comes with everything you need. It will help you to cut different sizes on different surfaces.

So, if you use hole saws frequently, this set is such a great option! The kit includes 22 different-sized cutting tools ranging from 0.75 inches to 4.75 inches. Moreover, the set includes 3 drill bits and 3 arbors. 

Best of all, these pieces come organized in a sturdy, plastic carrying case. As such, you can easily store them after use and carry them around. 

The best thing about this set is that it’s very simple to use. Not forgetting that you can use it to drill holes in different surfaces.

This includes thick metal, plaster, aluminum, plastic, and fiberglass. So, regardless of the material you’re working on, you’ll get the task done in no time. 

The hole saws feature bi-metal teeth with positive rakes, which are durable and stable. Thus ensuring more efficient and faster drilling. Also, since these chopper sets feature inbuilt precision, expect them to last for long. 

Moreover, the units feature ice-hardened construction. This increases their durability by up to 50% more than other tools

The only issue with this set is its price, especially if you don’t plan to use it regularly. However, for professionals and frequent users, it’s one of the best metal cutting holes saw on the market. 

Check the milwaukee hole saw kit 28 piece pros & cons below.

Pros 

  • Durable construction 
  • User-friendly 
  • Fast cutting and drilling 
  • Cuts through various materials, including thick metal and wood 

Cons 

  • A little pricey 

3. HYCHIKA Hole Saw Set: Best Hole Saw for Cutting Thick Metal

HYCHIKA Hole Saw Set

As far as price is concerned, very few hole saws can compete with this set from HYCHIKA BETTER TOOLS! Even better, the same case applies to its productivity and function. The set comes at a very reasonable price and offers features you may not find in other similar tools! 

For starters, this kit is well known for its incredible quality and unique design. But the most unique feature with these pieces is that they’ve got a unique black color.

In terms of construction, the pieces are crafted from heat-treated carbon steel material. Thus making them resistant to both rust and corrosion. 

Their teeth are highly serrated to ensure high performance. In addition, this helps in smoother and faster cutting with a 25mm depth. 

Another great thing about this set is that it’s very versatile. For that, you can use it on various surfaces. This includes plywood, plasterboard, thin PVC board, and softwood. It’s also ideal for cutting holes of different sizes on doors, furniture, and desk surfaces. However, this kit is not perfect for hardwood and metal. 

What does this kit come with? Well, you’ll get 2 drill bits, 2 mandrels, an installation plate, a hex key, and 13 different-sized hole saws.

You can use this kit to cut holes ranging from ¾” to 6” in diameter. Lastly, you’ll get a storage case for convenient storage and transportation of the tools. 

Pros 

  • Reasonable price 
  • Rust- & corrosion resistant 
  • Premium heat-treated carbon steel construction 
  • Multi-purpose set 

Cons 

  • Not ideal for hardwood and metal. 

4. Bosch HDG11 Hole Saw Set 

best hole saw for steel

Even though the Bosch HDG11 cutting kit is a newer model, it ensures maximum performance. The set comes with 11 pieces of cutting tools to give users an incredible cutting experience. 

But what we love most about these compatible tools is that they’ve many suitable features. The set includes chargeable arbors to ensure fast cutting. As such, with this kit, you can drill more than 6 holes within 15 minutes. 

Its Autostart pilot bit is spring-loaded to deliver the best outcome. Therefore, you don’t need a pilot hole to drill the surface. 

With the changeable teeth, you can adjust the tool to suit your needs. Also, the unit’s threadless design ensures that you don’t seize up with the included mandrel.

The other unique thing about this set is that it has incredible T-shark features. Thus making the den cutters easy to remove and insert. In terms of durability, this hole saw kit features a vacuum-brazed diamond grit.

This extends its durability and ensures faster cutting. Each saw contains carbon edge teeth for producing clean cuts. This also plays part in ensuring high-speed performance. 

In addition, the construction process of these units includes 8%cobalt. This gives them excellent heat resistance. Hence preventing the loss of durability in higher temperature circumstances. 

When it comes to versatility, this set works on various surfaces. It’s the best hole saw for steel, ceramic, granite, porcelain tiles, wood, and plastics. You can also use it on concrete surfaces, but it’s not designed for that! You’ll also get a sturdy plastic case for convenient transportation and storage. 

Pros 

  • Time efficient 
  • High-quality tips 
  • Cuts easily and effectively 
  • Produces clean cuts 
  • Ideal for cutting different materials 

Cons 

  • You’ll need a 3/4” bit 

5. SUNGATOR Bi-Metal Hole Saw Kit 

SUNGATOR Bi-Metal Hole Saw Kit

If you work with metals a lot, then this SUNGATOR hole saw kit is something you need in your workshop. It’s a high-quality set that has been designed to ensure speedy cutting of thin gauge metals and plastics.

Besides, the fact that it works with impact drivers makes it an even better option! 

The best thing about this kit is that its pieces have a bi-metal construction system. As such, it’s much stronger and durable than most holes in the market. For this reason, you can use it to cut thicker metals and it will not wear out faster. 

Moreover, the pieces feature high-speed blades and a long-lasting carbon body. This means that they are both heat-resistant and rust-proof. 

You’ll also note the included saws have pointy and sharp teeth. Therefore, you can use the set to cut through your materials cleanly and smoothly. 

Once you buy this kit, you’ll get a hard carrying case, pilot bit, and a mandrel adapter. More importantly, you’ll get 10 hole saws of different sizes to use in various situations. 

The blades are ideal for cutting depths ranging between 1.7” and 2”. But this will depend on the size of the bit! They are ideal for making efficient cuts through materials. They work on metal, drywall, plastic, PVC board, and wood. 

Lastly, this set is very simple to operate. Besides, the saws are compatible with many drills from various manufacturers. 

Pros 

  • Rust- and heat-resistant 
  • Cuts both metals & plastics 
  • Very affordable 
  • Works well with impact drivers 
  • Delivers incredible and fast cuts 

Cons 

  • The saws get dull faster 

6. DEWALT D180002 Hole Saw Kit 

DEWALT D180002 Hole Saw Kit

If you’ve been in the metal-working industry for a long, we’re certain you’ve come across a DEWALT product. Besides, it’s one of the most reputable brands in the industry. So, you can rest assured you’re getting a quality kit by buying their D180002 model! 

Apart from coming from a reputable manufacturer, this set has many great features! As the best hole saw for metal, it comes with everything you need to handle your metal cutting activities.

It includes 9 different-sized metal blades and large & small quick–change mandrels. Best of all, even with all these pieces, this kit is very affordable! 

Moving on to construction, the cutting tools have thick & hardened backplates. They’re made with premium-grade M3 steel to ensure quality. These factors make them ideal for delivering fast cutting of various materials.

You can use them to cut plastic, wood, and even metal, without distorting. Moreover, they have a unique tooth form to enhance their chip removal.

You’ll also love that these saw’s C-clamp design. This enables you to clamp the saw on the surface tool-free, without damaging it. Moreover, the saws have lofty bushings and alignment windows. This ensures precise height placing as well as vertical drilling. 

It’s also worth mentioning that these cutters have extra-deep gullets. This is something you may not see on most brands. This means that you’ll be able to cut more in-depth as compared to other cutting tools. This enhances its versatility by ensuring quick and clean cuts across various materials. 

Pros 

  • Heavy-duty & durable bi-metal construction 
  • Clamps tool-free 
  • Extra-deep gullets
  • Portable carrying case 
  • Affordable 

Cons 

  • Included mandrels aren’t that durable 

7. Tacklife Hole Saw Kit 

Tacklife Hole Saw Kit

As a DIYer, you probably don’t want an expensive set that’s intended for professionals. Instead, you should look for a reasonably priced set that gets the job done. In that case, you should consider buying this kit from Tacklife! 

Apart from being affordable, this kit comes with a total of 17 pieces of common hole-cutting blades. You can use them to cut surfaces to a depth of up to 25mm. Also, these blades are available in different sizes ranging from ¾” to 5” in width. 

You’ll also get 2 different-sized mandrels with changeable pilot bits. Moreover, the kit includes a hex key wrench for tightening or removing the mandrel bits. There is also an installation plate that you can use with the large blades. 

For convenient storage and transportation, the set includes a hard plastic box. The only issue with this box is that it doesn’t have a handle. other than that, it ensures safe storage of your cutter blades. 

These blades are crafted from heat-treated carbon steel. This makes them wear- and impact-resistant. This coating also preserves the blades and extends their useful life.

In terms of appearance, they’ve got a very appealing black coating. So, even when the paint peels off after repeated use, the tools will still look neat. 

You can use these circular blades on plastic, thin PVC boards, softwood, and plywood. However, it’s not designed for hard materials like stone, density board, and aluminum. 

Pros 

  • Durable carbon steel construction 
  • Fairly priced 
  • Includes many commonly used hole blade sizes 
  • Wear & impact-resistant 

Cons 

  • Not ideal for cutting harder wood 
  • Carry case lacks a handle 

8. CRAFTSMAN Hole Saw Kit 

CRAFTSMAN Hole Saw Kit

Have you ever wondered why some hole-cutting kits are more expensive than others? Well, that’s partly because most of them include more incremental sizes, you may never even use. 

So, to help you save some money, consider investing in a set that only comes with the common sizes. In that case, this kit from CRAFTSMAN is one of the best metal hole saws out there! 

It only comes with 6 sizes of cutting blades, ranging from 1” to 2.5”. As you know, these are some of the most common hole saw sizes for various metal cutting applications. 

Also, the set includes a mandrel with an adapter. Thus making it compatible with larger hole saws. In short, you’ll not get extra accessories like pilot bits and arbors in this kit. For this reason, you’ll find out that this set is much cheaper than other kits. 

The other great thing about these tools is that they’re bi-metal. This simply means that they’re crafted from 2 types of steel. Moreover, their bodies are formed into cups and made up of spring steel. 

The front edge of the cup then features a circular raw of teeth crafted from high-speed steel. This design results in a durable, tough, and lightweight accessory. It’s ideal for making big holes both in metal and wood. 

Overall, this kit delivers solid performances. Even better, it contains high-quality bits, yet it’s very affordable. 

Pros 

  • Comes at an affordable price 
  • Ideal for metal and wood cutting applications 
  • Durable and high-quality bits 
  • Bi-metal construction 

Cons 

  • Doesn’t include a carrying case

9. Diablo DHS14SGP Hole Cutting Set 

Diablo DHS14SGP Hole Cutting Set

Diablo is another popular brand that is known for producing some incredible blades. Thankfully, their hole saw set is not an exception! Just like any other Diablo tool, this set features high-quality Diablo construction. 

But that’s not even the best thing about this kit!

For one, it comes with 10 different-sized bi-metal tools, ranging from 7/8” to 2- 9/16”. Also, you’ll get 2 adapter nuts (1/2” & 5/8”), a mandrel, and a pilot bit. 

These tools come packed in a strong, durable plastic carrying case. As such, you can easily store and carry the set around! 

The teeth of each cutting blade have been advanced. This ensures fast cutting of materials and high performance. To show you fast this tool is, its cutting speed is 10X faster as compared to other tools! 

In terms of depth, each saw can cut deeper holes of up to 2.375” in one pass. And you can use it to drill holes in different materials. It’s ideal for drilling harder wood, plastic, aluminum, metal, and stainless steel. 

We also love that each unit has slots to help you remove wooden/ metal chips and plugs tool-free. Better still, the quick-connect mandrel features a 1-size design. Therefore, it is compatible with all blades. This, plus the snaplock mandrel system guarantees fast mounting of the cutters. 

As a drawback, this set includes the less-than-common circular blade sizes. However, if you’ve got these unique cutting needs, don’t hesitate to buy this kit. The saw sizes it comes with are a bit difficult to find! 

Pros 

  • Cuts through different materials 
  • Easy material and plug removal 
  • Hard-to-find size range of hole saws
  • Faster cutting speed and durable cutting life 

Cons 

  • Doesn’t include some common sizes 

10. Bosch Hole Saw Kit (HCS008) 

Bosch HCS008 Hole Saw Set

Again, there is no need of buying a set with many pieces, knowing you may never use some of them. However, you should always settle for the best hole saw kit for metal. 

And the best way to ensure that is by choosing a product from a reputable brand like Bosch! That being said, their HCS008 model is one of the best sets that only contains the commonly used pieces.

To be precise, the bosch hole saw kit includes 7 pieces of hole saws, with their sizes ranging from 1” to 2.5”. However, you’ll also get a pilot bit and an arbor. 

One notable feature about these blades is that they’re 5 times faster than standard tools. Thanks to the unique turbo-teeth design on each blade.

The small teeth have been advanced to deliver clean cuts when working on thin material. Contrarily, optimization of the large teeth delivers fast cutting in thick surfaces. 

Besides, the blades feature an extra-large wood/metal chip clearance slot. Thus ensuring long life as well as high-speed performances in various applications. 

Looking at the construction, the shoulder of each blade is reinforced. This gives them extra strength and extends their durability. This is also promoted by the fact that the unit is made up of 8% cobalt. Apart from giving it a longer life, this increases its heat resistance. 

Lastly, each unit has a standard circular blade system. For this reason, you can use it in quick change and standard arbors. And did we mention that you’ll also get a carrying case? That way, storing and transporting the pieces will be easy! 

Pros 

  • Strong & long-lasting design 
  • Cuts different materials faster and cleanly 
  • Quick change arbors 
  • Convenient carrying case 
  • Affordable 

Cons 

  • May lack some size options one might need

Buyer’s Guide for The Best Hole saw for Metal 

Now that you know the best hole saws out there, which is the right one for you? Before you make that decision, there are certain factors you need to consider. It’s only by considering these factors that you’ll find a kit that works perfectly for you. Here are some of those factors; 

Brand 

As far as metalworking tools are concerned, it’s always good to buy products from a reputable brand. Choose a set from a manufacturer that provides servicing and customer satisfaction. Also, make sure you look out for reliability and quality.

Why are emphasizing the importance of buying a well-known brand? Simple! Not every manufacturer out there makes reliable equipment! While reputable brands usually come at a higher price, trust us, it will be worth it in the long term. 

Cutting efficiency 

Since you’re buying a kit for drilling or cutting holes into surfaces, you can’t overlook this factor. In other words, the set should be able to cut or drill through the material you’re working on efficiently. In this case, that type of material is thick metal. 

Remember, different hole saw sets have different cutting efficiency. Besides, some blades become inefficient or dull with time. We suggest you avoid such types of hole-cutting kits! 

Instead, choose a tool with strong teeth and high cutting efficiency. As such, you’ll be able to cut through materials continuously without damaging the blade. 

Longevity 

A hole saw kit is not something that buyers want to buy after every few weeks or months! Instead, users want a set that will serve for an extended period of time.

That’s why you should check for the product’s durability. To know whether the kit is durable or not, look out for things like build quality, and materials.

Although durable units have high buying costs, they’re cost-effective in the long run. So, don’t let price hinder you from investing in a high-quality, durable set! 

 Your cutting needs 

Different products are intended for handling different tasks. For instance, a hole saw set that is designed for plastic may not work on metal or wood.

However, a set that can cut through metal can also work on plastic. So, it’s good to buy a tougher tool that you think you’ll need!

And seeing that you intended to work on thick metal, that’s is the only option you have. Lucky for you, you don’t have to go through that problem! That’s because every set on our list is ideal for cutting through thick metal. 

Frequently Answer Questions About Hole Saw

#1. How do you drill a hole in thick metal?

Provided you’ve got the right hole saw, drilling thick metal is quite simple. That’s because it has specialized teeth that provide a tight grip on the material. 

Start by placing your hole saw into a drill. After that, put its drill pit into the pilot bit. Now, cut through the material as you hold it firmly until it cuts through into the other side. Stop your drill, let the bit stop turning, and lift the hole saw from the material. 

#2. Can you use a hole saw on metal? 

A quality bi-metal hole saw cuts through hard materials. This includes materials like stainless steel and thin-gauge metal. However, remember that not all tools are designed for cutting metal. 

#3. Will a diamond hole saw cut steel? 

Diamond hole saw sets are ranked among the most hardened drill bits available. However, they’re only ideal for cutting through certain materials like ceramic. For instance, when used on steel, the entire bit clogs and causes the tool to overheat.

This will eventually damage the entire bit. And considering how costly diamond versions are, we don’t think that’s what you would want. So, we don’t recommend the use of diamond bits to cut steel! 

#4. Is it possible to cut metal with hole saws without using a pilot bit? 

Yes! In fact, when you’re drilling fragile/ very thin materials, you shouldn’t use a pilot bit. That’s because it can split or crack such surfaces.

However, a pilot bit acts as a guide. Thus, centering the saw without it will be a challenge. The other benefit of using a pilot bit is that it prevents the hole saw from sliding to the side during use. 

#5. How do you measure a hole saw? 

You can measure them with 2 major aspects; cutting speed and bit diameter. Cutting speed is the speed at which it cuts through a certain material. While bit diameter refers to its size, usually expressed in millimeters (mm)/ inches. 

Conclusion 

Cutting perfect circles through thick metal by hand is almost impossible. That’s why many professionals and DIYers choose to look for a hole saw set instead. Besides, it’s only by having the right tools that you can get any task done properly. 

To find the best hole saw for cutting thick metal, you just need to go through our extensive reviews. We have listed some of the best models available in the market today.

Best of all, we’ve included the important aspects that will help you chose the ideal kit for your needs! 

Leave a Comment

Your email address will not be published. Required fields are marked *