thailazer

Just starting a project and was going to use the hole cutter to make some lightening holes in a some lite ply fuselage sides. Even using the hole cutter, the lite ply will splinter and not leave a finished look. What methods are good for making 1 inch to 2 inch holes in light ply that leave a nice sharp edge with no splinters?

foodstick

I think your best bet is to find a fine tooth holecutter.. or maybe they make one with more of a grit? than teeth... Also I have had the same kind of issues and often use a sanding drum to go in and clean up the edges after the hole saw.

I never mentioned also this is probably easier on a drill press, than a hand held. I hope you get it perfected and keep building !

3dorbust

A router with a flush cut bit make a round template first that the router will run inside mount it with clamps or wood screws

Hydro Junkie

A hole saw run part way through on both sides normally cuts a clean hole. Another option is to use a hole saw one size smaller and drum sand to finished size as Foodstick recommended. I've done both with good results though, when it comes to the sanding, I use this drum/horizontal belt sander to finish the holes:

flyboy2610

My Feedback: (1)

Use a drill press, use a backer block for the lite ply, use a hole cutter, and when the teeth are a bout halfway through the ply, flip it over and finish the hole from the other side. It still may need a little sanding to clean up, but it will look a lot better.

thailazer

Hey, Thanks all for the suggestions! I think I am going to grind down my hole cutter as it is indeed way to aggressive. Backing plate is a good idea too, and I do usually cut in from both sides. Appreciate the help.

All Day Dan

My Feedback: (5)

I uase a forstner bit. Dan.

rrembert

+1

Hemikiller

My Feedback: (125)

A good sharp Forstner bit should give you a reasonable finish. The cylindrical hole saws have too low a tooth count.

FlyerInOKC

My Feedback: (6)

I wonder if one of these would work?

Hobbico Circle Cutter

thailazer

I think you have hit on the best way to cut those holes! A bit more time and equipment involved but those router bits do indeed produce a clean cut. Do you have a source for 1/8 inch shank router bits with the ball bearing for use with a Dremel tool? Been looking and have not found one yet. That would be handier than a bulky router with the larger shank.

For now, I have found that my Milwaukee hole cutter does a decent job if I run the drill backwards. Thanks again for all the inputs.

Truckracer

My Feedback: (19)

Large Forstner bits will make perfect clean cut holes that look like they were cut with laser precision. The bits are a bit expensive but well worth it if you are cutting quite a few holes. I have bits from below 1/4" to over 1.5".

For relatively soft woods like Lite Ply or balsa, you can also make a hole cutter from a piece of thin wall SS tubing of the correct size. You sharpen one end of the tubing from the inside and afix the other end to some kind of handle. Rotate the tubing against the wood using light pressure and it will cut like a die. You can get very clean cut holes using this method. Brass tubing works well for smaller holes.

acdii

Forstners here too. I found that cutting from both sides gives the cleanest cut, very little sanding needed.

Truckracer

My Feedback: (19)

Yes I forgot about cutting the holes from both sides. Good call! Otherwise the bit may catch on the thin ply and tear it.