5 Best Hole Saws for Cutting Thick Metal
It is a given among anyone who uses tools regularly that having the right tool for the job is essential to a good result. This adage is never truer than when you are cutting thicker metal. Getting the best and cleanest cuts is almost entirely dependent on having the best hole saw possible.
Cutting metal with a hole saw takes a special tool specific to the job. Metal hole saws for cutting thicker metal are typically cobalt. Cobalt dissipates heat quicker than other metals. Heat is the enemy of your hole saw when cutting thicker metal. Other materials will work but require different techniques for cutting thicker metal.
The best hole saws for cutting thick metal are the Klein Tools 31872, Dewalt DWA1802, and EZARC Carbide Hole Butter. Kits like the Diablo DHS14SGP 14 Piece set can cut thick metal and wood. The Greenlee Carbide Cutter is one of the 5 best hole saws for cutting thick metal.
Best Hole Saws For Metal
| Brand and Model | Cutting Edge Material | What is in the Kit? | Best Selling Points |
| Klein Tools 31872 Hole Cutter 4 piece set | Carbide Tipped | 7/8-inch, 1-1/8-inch, 1-3/8-inch plus one extra pilot bit | Best electrician hole saw kit. Most popular sizes for conduit and pipes |
| Dewalt DWA1802 2X Electricians Hole saw Set – 9 Pieces | Cobalt | 7/8-inch, 1-1/8-inch, 1-3/8-inch, 1-3/4-inch, 2-inch, 2-1/2-inch, quick-change mandrel, plus one extra pilot bit | Fast cutting tooth design when time is critical |
| EZARC Carbide Hole Butter Set 6 Piece for Hard Metal | Tungsten Carbide Tipped | 7/8-inch, 1-1/8-inch, 1-3/8-inch, 2 piece pilot bit set, 1 hex key | Industrial grade hole saw bits combining stainless steel with tungsten carbide teeth |
| Diablo DHS14SGP 14 Piece Performance Hole Saw Set | Blended Metal | 7/8”, 1”, 1-1/8”, 1-3/8”, 1-3/4”,2-1/8”, 2-9/16”,3”, 3-5/8” 4-1/8”, 1. Mandrel, 2 Pilot bits, 2 adapter nuts | The Diablo Snaplock mandrel makes changing blades quick and painless |
| Greenlee – Carbide Cutter, Quick Change, 6Pc, Hole Making (660) | Carbide | 7/8”, 1-1/8”, 1-3/8”, 1-3/4”, 2” cutter heads, 1 mandrel, I hex key | Includes a cobalt replaceable pilot bit with split point design |
There are many hole-saw kits available in the market. Some of these kits seem like incredible values. Don’t be mislead. Cutting tools are only as good as their materials. You may find cutting tools that seem like amazing deals only to learn that they won’t cut or don’t hold a good edge. Hole saws are no different. Our guide can help you find the best hole-saw for your applications.
Klein tools are made in America using the finest premium quality materials and metals. Professionals in all categories of the trades have been using Klein tools for many years. Klein prides itself on producing professional tools for professional craftsmen. Many homeowners and DIY’ers chose Klein tools as well for the same reasons.
You can find the Klein 31872 hole cutter 4-piece set in many electricians and plumbers tool kits. This four-piece set of metal cutting tools contains the most popular sizes of hole-saws for running electrical wire, conduit, and piping.
What Makes This Kit a Good Buy?
The feature of the Klein four-piece hole saw kits that grab our attention is the longevity and dependability. Klein tools last. You won’t find yourself running to the tool store every job to replace a Klein hole saw blade. This kind of dependability is what has made Klein the first choice among professionals. The features included with this Klein hole saw set are the best explanation.
- Handle cutting chores in stainless steel, mild steel, iron, copper, and brash up to 3/16-inch thick with ease
- Split point pilot bit reduces or eliminates bit walking
- Integrated flange on the bit provides a positive stop to prevent over-drilling
- Includes a rust-proof poly storage case with positive tool holders to keep your hole saw safe and secure.
What Other Users Say About this Hole Saw Set?
It is hard to find any Klein tool user with negative comments or experiences with a Klein tool. By and large, users of Klein tools rave about their choice.
- Most users of the Klein four-piece hole saw kit find the design of the hole saw bits exceptional.
- Many users find the ejection spring and pilot bit a great combination making starting and finishing holes easier.
- The longevity of the Klein hole saws gets many mentions.
The Final Words
Klein tools should be on any list of the best tools. This opinion is especially true of these hole saw kits. No list would be complete without a Klein tool somewhere in the mix. Our impressions of the Klein 31872 Hole Cutter 4-piece set are easy to summarize.
- High quality for a good price. Not the cheapest but certainly well worth what you pay for these tools
- Carbide-cutting teeth will handle almost any material you may face.
- Thoughtful design for easy starting, easy cutting, and clean results
- Long cutting life
Consistency is performance is a plus in any tool. Opting for a Dewalt hole saw kit ensures consistency of performance for any job. The Dewalt DWACM1802 hole saw kit will provide you with that maximum consistency in job performance.
Dewalt has married stainless steel with carbide teeth to give long life dependable cutting, and clean results with this hole saw kit. This Dewalt metal cutting hole saw set can hold its own against any challenging job. The unique design of these bits ensures fast cutting with lower temperatures for longer life.
What Makes This Kit a Good Buy?
Dewalt has put a lot of design thought into their metal cutting hole saws. This Dewalt nine-piece hole saw kit combines the best features to provide anyone, professional or hobbyist, with long tool life and consistent tool performance on the job. Consider these features that are standard on this Dewalt DWA1802 Hole Saw Kit.
- Staggered slots make plug removal easier and faster
- The deep cut design allows penetrating thick material easier and quicker
- 75 percent cobalt content means cooler cutting and longer blade life
- Made in the USA and includes a 30-day warranty
What Other Users Say About this Hole Saw Set
You find very few products that don’t have at least a few negative comments. Not so the Dewalt DWA1802 Electricians Hole Saw Kit. We couldn’t find a single negative review about this set of hole saw bits. Users of these hole saw kits consistently rave about the performance and longevity of these hole saw bits.
- Users report faster cutting with these bits than other bits they have used
- The consistency of the cutting gets many mentions.
- The quality of manufacture by Dewalt is a common comment
The Final Words
Dewalt tools are a staple on many job sites. Some contractors and many homeowners stock their tool chests with Dewalt tools exclusively. Choices like this are a testament to DeWalt’s reputation for dependability and toughness. The factors that put this hole saw kit on our list include:
- Dewalt’s reputation for consistent quality and great customer support
- Cobalt material in the bits for cooler cutting and longer life
- Unique staggered slot design for faster cutting and plug removal
- A wide selection of bit sizes provides a more flexible toolset for most users
These industrial-grade deep-cut carbide hole saws offer superior cutting for quicker and easier jobs. EZARC designs their carbide-toothed hole saws for long life and heavy use. The stainless steel backs and carbide teeth are durable, tough, and dependable.
EZARC gets high review numbers among the purchasers of these tools. Although EZARC is not a well-known brand name, their products get positive feedback in almost every case. This EZARC 6 piece hole saw kit offers great value for the occasional user and should provide long service.
What Makes This Kit a Good Buy?
Value is the keyword in this selection from our best hole saw for the thick metal list. Any kit that includes this selection of stainless steel hole saw bits with tungsten carbide cutting teeth should cost much more. The EZARC kit is a great addition to any shop or job site where the occasional need for a hole in thicker metal rises. You won’t find a lack of features with the EZARC kit.
- Industrial grade hole saw offers 10x the life of a comparable bi-metal blade
- Tungsten carbide teeth resist breakage
- Fast, precise cuts in stainless steel, sheet metal, cast iron, mild steel, aluminum, and FRP
- Precision engineering for precise clean cuts
What D0 Other Users Say About this Hole Saw Set?
The EZARC carbide-tipped hole saw kit handles the most demanding cutting challenges. The design includes all the features of much more expensive hole saws. If you don’t want to bust your budget but need a good set of metal cutting hole saws, this kit from EZARC is a good choice. Users of these hole saw bits provide insight into the quality you can expect
- Users consistently remark on the quality of the manufacturing in these hole saws.
- Many purchasers of this hole saw kit comment on the precision of the holes even on thicker metal
- Comparisons to other manufacturers hole saws by users of the EZARC hole saw kit are positive and, in some cases, rate the EZARC superior
- Most users find the price to value ratio great
The Final Words
Finding industrial-grade tools at a value price can be a challenge. EZARC has made the challenge easier with its six-piece EZARC Carbide Hole Cutter kit. It makes our list of the best hole saws for cutting thick metal on several points.
- High-quality stainless steel and tungsten carbide construction
- Fast precision cutting
- Durable design for long life and consistent performance
- Great value for the cost of purchase
Diablo is well known for its saw blades but less recognized for its other cutting tools. You shouldn’t overlook the Diablo DHS14SGP 14 piece hole saw kit. Diablo has applied their knowledge of cutting successfully to this line of hole saws.
The biggest advantage to the Diablo 14 piece hole saw kit is the Snaplock mandrel design. Faster bit changes with no tools offer quicker job turnaround and less frustration. Tool-free plug ejection is also a great feature of these hole saws.
What Makes This Kit a Good Buy?
There are many reasons that the Diablo 14 Piece hole saw kit makes our list of best hole saws for thick metal. Among those reasons are:
- The snaplock mandrel design for easy and quick blade changes
- A larger assortment of bit sizes that fit one mandrel and a reasonable price
- Blended metal construction for long blade life and clean cuts
- Extra deep cutting capacity for use on thicker materials
What Other Users Say About this Hole Saw Set?
Diablo products get consistently high ratings among those who review their products. Among the most common comments about the Diablo 14-piece hole saw kits are:
- The tooth design and set cut quickly and easily, even in the hardest materials
- The Snaplock mandrel design gets high marks from users for easy bit changes
- The large selection of bits included in the kit gets a positive nod from purchasers
- Well-constructed for durability.
The Final Words
Diablo is a go-to choice for saw blades for many professionals and homeowners alike. The reputation of Diablo makes choosing a Diablo hole saw kit a wise choice. The Diablo 14 piece hole saw kit makes our list of the best hole saws for thick metal for several reasons.
- Deeper cut capacity for thicker material
- Snaplock mandrel design for quick and easy bit changes
- A larger number of kits with the kit for greater convenience
- A tooth design that cuts quickly
There is no doubt that Greenlee is a well-known maker of professional-grade tools, especially for the electrical industry. It is no wonder that the Greenlee Carbide Cutter hole saw kit with quick-change mandrel is a sure bet for any toolbox.
The Greenlee 660 Hole Saw Kit delivers the expected quality and precision anyone expects from a Greenlee tool. The quick-connect mandrel design is sturdy and dependable for years of use on the job. The cobalt split-point pilot bits are replaceable and make starting your hole in the right place a breeze.
What Makes This Kit a Good Buy?
You will never go wrong with Greenlee tools. I admit you may pay a premium for these tools. However, what you get for that premium price is often worth more than you pay. The quality of materials, construction, and service you get from Greenlee offset any extra cost.
- Ejector spring equipped for easier plug removal
- High strength cobalt-steel pilot bits and carbide-tipped cutting teeth
- . Quick change mandrel design
- Flange stop equipped to prevent over-drilling
What Other Users Say About This Hole Saw Kit?
Greenlee gets above-average reviews on its 6-piece hole saw kit from both professionals and casual users alike. Surveying these reviews reveals what these users like about these Greenlee tools.
- These kits easily handle cutting through stainless steel countertops and metal counter coverings
- By all accounts, these bits run cool and cut clean even under the most arduous uses
- The economy in the Greenlee hole saw set is in its longevity. These bits cut far longer than bi-metal bits and usually last longer than other carbide bits
How To Resharpen Hole Saw Bits
Many people consider a hole saw a drill bit. This is a wrong assumption as hole saws are true saws. As with any saw, you can resharpen a hole saw using the proper tools and methods. Resharpening any kind of saw has three steps.
Step 1: Use the right tools
You will need a flat file and a triangular file to sharpen your hole saw teeth properly.
Step 2: Set the Teeth to the Right Angle
Every saw has a tooth angle the determines the kerf of the saw cut. You should set the kerf angle of your saw teeth appropriately for the cutting the saw performs.
Step 3: Dress the Tips for best Results
Use your flat file to touch up any of the teeth that have burrs or uneven tips. The dressing allows the hole saw teeth to ride smoothly over the material’s surface and eliminates binding and catching.
Related Questions
Should I Use Oil When Cutting Metal with a Hole Saw?
Generally, it is good to use some lubricant when you are cutting metal with a hole saw. Cutting oil keeps the cutting bit and your metal project cooler. The cooler you can keep your hole saw blade, the longer it will last and the cleaner it will cut. Keeping your project metal cool lessens the chances of warping or discoloration from the heat.
What is the Difference Between Bi-Metal and Carbide Hole Saws?
The body of bimetal hole saws is made of high-carbon steel with high-speed cutting steel teeth. This combination provides the optimum in cutting speed and durability. Finding a bimetal blade that uses cobalt as part of the alloy material can help eliminate the blade’s overheating as it cuts.Carbide-tipped hole saws use a tungsten carbide cutting edge that is mechanically attached to the bit’s body. Many carbide tipped hole saws use cobalt or stainless steel material for the bit’s body to help dissipate heat.In general, carbide-tipped hole saws do better in harder and thicker materials than bi-metal hole saws. However, carbide-tipped hole saws are also more expensive and more prone to damage than bi-metal blades.
Getting the Most Out of your Hole Saw
Choosing the right tool for your job is the key to getting the most out of your hole saw. Hole saws come in a variety of sizes, types, and materials. In general, for cutting holes in thicker metal, carbide-tipped hole saws are the best choice. Those with cobalt alloys usually will perform better and longer, especially if lubricated while cutting.
We hope that this article helps you make the best choices when selecting hole saw kits for your thick metal project. Remember to follow the manufacturer’s instructions when using your hole saw and practice good shop safety.
Dennis is a retired firefighter with an extensive background in construction, home improvement, and remodeling. He worked in the trades part-time while serving as an active firefighter. On his retirement, he started a remodeling and home repair business, which he ran for several years.
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