Holesaw Sets

About Holesaw Sets

Holesaw sets are indispensable toolkit additions for tradespeople and DIY enthusiasts who regularly need to cut clean, accurate holes through various materials including wood, metal, plastic, composite boards, and masonry. Rather than purchasing individual holesaws as needed, a comprehensive set provides a range of the most commonly used diameters in one convenient package, typically stored in a robust carry case for easy transport between jobs and organised storage on site or in the workshop. These versatile cutting tools excel at creating precise circular openings for applications ranging from electrical installations and plumbing work to kitchen fitting and general construction tasks.

A quality holesaw set includes not just the cutting heads themselves, but also the necessary arbors (mandrels) and pilot drill bits required to guide the saw and create precise holes. Professional-grade sets from brands like Bosch Professional, DeWalt, Bahco, and Makita feature bi-metal construction with hardened teeth for enhanced durability and cutting performance across multiple materials. The selection at Tooled-Up.com includes specialist sets tailored for specific trades—electricians' holesaw sets focus on smaller diameters (16mm-76mm) suitable for back boxes and downlighter installations, whilst plumbers' sets include larger sizes up to 152mm for waste pipes and soil stacks. Multi-purpose contractor sets offer broader size ranges covering the most frequently required diameters for general construction work.

Premium sets often incorporate advanced features such as quick-change systems that allow rapid switching between holesaw sizes without requiring spanners or additional tools—Bosch's Power Change system being a popular example that saves valuable time on site. Diamond-coated and carbide-tipped specialist sets are available for cutting through challenging materials like ceramic tiles, glass, and cement board. Whether tackling professional contracting work or occasional home improvement projects, investing in a comprehensive holesaw set delivers better value than purchasing individual components whilst ensuring you always have the correct size to hand when needed.

Jargon Buster

Bi-Metal Construction

Holesaws manufactured from two different metals, typically a high-speed steel (HSS) cutting edge welded to a flexible spring steel body. This combination provides excellent cutting performance with reduced risk of tooth breakage, making them suitable for cutting both wood and metal. The 8% cobalt content in premium bi-metal holesaws significantly increases wear resistance.

Arbor (Mandrel)

The shaft assembly that connects the holesaw to your drill or power tool. It includes the pilot drill bit that centres the cut and the threaded section that the holesaw attaches to. Quality sets include multiple arbor sizes to accommodate different holesaw diameters, with some featuring quick-release mechanisms for tool-free changes.

Pilot Drill Bit

The small drill bit located at the centre of the arbor that creates a guide hole before the holesaw teeth engage with the material, ensuring accurate positioning and preventing the saw from wandering during cutting. Replaceable pilot bits are available in various lengths for cutting through thicker materials.

Variable Pitch Teeth

Holesaws featuring teeth of different sizes arranged around the cutting edge. This design reduces vibration, provides smoother cutting action, and helps prevent tooth breakage when cutting through materials of varying hardness. Professional Sandflex bi-metal holesaws typically feature this advanced tooth geometry.

Power Change System

A tool-free arbor system allowing rapid switching between different holesaw sizes without requiring spanners or additional tools. This technology significantly speeds up workflow when frequently changing between diameters, making it particularly valuable for electricians and kitchen fitters working on multiple installations.

Kerf

The width of material removed by the holesaw teeth during cutting. A narrower kerf removes less material, requiring less power from your drill and producing less waste, though extremely narrow kerfs may be more prone to binding in thick materials or metals.

Who Uses Holesaw Sets?

Holesaw sets are essential tools for a wide range of trades and applications:

• Electricians and Sparkies: Installing back boxes, cable entry points, downlighters, recessed spotlights, and electrical accessories in walls, ceilings, and control panels
• Plumbers and Heating Engineers: Creating pipework entry points through joists, walls, and floors for copper pipes, waste pipes, radiator feeds, and soil stacks
• Carpenters and Joiners: Door furniture installation, cable management holes, lock fitting, and general woodworking applications requiring clean circular cuts
• Kitchen and Bathroom Fitters: Tap holes in worktops, waste outlet holes in sinks and basins, and accessory mounting in various materials including laminates and composite boards
• General Builders and Contractors: Wide range of site applications requiring clean holes through construction materials including plasterboard, timber, and masonry
• HVAC Engineers: Ductwork penetrations, ventilation grille installations, and air conditioning pipework access holes
• Shop Fitters and Glaziers: Display unit installations, hardware mounting, and cable management in retail environments
• Maintenance Engineers: Repair work and modifications requiring access holes in industrial and commercial settings
• Facilities Managers: Building maintenance, upgrading electrical installations, and general building modifications
• DIY Enthusiasts: Home improvement projects including lighting installation, plumbing upgrades, kitchen renovations, and general household repairs

How to Choose the Right Holesaw Sets

Consider Your Primary Applications

Trade-specific sets are tailored to the most common hole sizes for particular professions. An electrician's set typically ranges from 16mm to 76mm, ideal for back boxes, downlighters, and cable entry points, whilst plumbers' sets include larger diameters up to 152mm for waste pipes and soil stacks. Multi-purpose contractor sets offer broader size ranges suitable for general builders and DIY users who tackle varied applications. If you specialise in kitchen and bathroom installations, consider diamond-coated sets specifically designed for cutting tiles and ceramics.

Material Compatibility

Bi-metal holesaws handle both wood and metal, making them versatile choices for most applications. For specialist materials, consider dedicated options—diamond-coated holesaws excel at cutting tiles, glass, porcelain, and ceramics, whilst carbide-tipped versions tackle abrasive materials like fibreglass, cement board, and composite materials. Standard HSS holesaws are adequate for softwoods and plastics but wear quickly in metals.

Build Quality and Durability

Professional users should invest in premium sets from Bosch Professional, DeWalt, Bahco, or Makita featuring robust construction, replaceable pilot bits, and durable storage cases. These withstand intensive daily use and maintain cutting performance over hundreds of holes. Premium bi-metal holesaws with 8% cobalt content offer superior wear resistance compared to standard HSS. Tooled-Up stocks sets ranging from occasional-use options through to professional contractors' kits designed for demanding site work.

Arbor Configuration

Check what arbors are included and whether they suit your existing power tools. Quick-change systems significantly speed up work when switching between sizes frequently—particularly valuable for electricians fitting multiple downlighters or kitchen fitters installing numerous appliances. Traditional threaded arbors are universally compatible and easily replaced if damaged, though they require spanners for changes.

Storage and Organisation

A quality case keeps your set organised, protects the cutting edges during transport, and makes it easy to identify missing sizes at a glance. Look for clearly labelled storage with secure closures suitable for site conditions, and foam inserts that hold each component securely. Robust carry cases are essential for mobile tradespeople moving between multiple jobs daily.

Set Composition

Consider how many pieces you genuinely need. Larger 14-16 piece sets offer better value per holesaw but may include sizes you'll rarely use. Analyse your typical jobs to determine whether a focused 6-11 piece set or a comprehensive collection better suits your requirements. Most electricians find 10-11 piece sets ideal, whilst plumbers benefit from larger collections including 100mm+ diameters.

Power Tool Compatibility

Ensure your existing drills have sufficient power for the holesaw diameters you'll be using. Modern 18V cordless drills from Makita, DeWalt, Milwaukee, and Bosch provide ample torque for holesaws up to 65mm diameter. For larger holesaws (100mm+) or frequent use in tough materials like stainless steel, a mains-powered 240v drill offers sustained power without battery limitations.

Popular Accessories

• Individual Replacement Holesaws: Replace worn or damaged sizes from your set without purchasing an entire new kit—available in all standard diameters
• Additional Arbors: Spare arbors prevent downtime if your original becomes damaged, plus extended-reach versions for cutting through thicker materials like double walls
• Replacement Pilot Drill Bits: Pilot bits wear over time and are available in various lengths and diameters to suit different arbor systems
• Holesaw Accessories Kits: Adaptors, extensions, and conversion accessories that increase versatility and allow use with different power tool systems
• Cutting Lubricants and Wax Sticks: Specialist lubricants extend blade life dramatically and improve cutting performance when working with metals and stainless steel
• Plug Ejection Springs: Help remove material plugs that become stuck inside holesaws after cutting, particularly useful with deeper cuts
• Magnetic Holesaw Arbors: Magnetic retention prevents holesaws loosening during operation, particularly when cutting through vibration-inducing materials
• Power Tool Side Handles: Additional handles and depth stops for improved control and accuracy when cutting larger diameter holes
• Drill Stands and Guides: Portable drill stands ensure perfectly perpendicular cuts and improved safety when using larger holesaws
• Holesaw Storage Solutions: Aftermarket organisers, wall-mounted racks, and drawer inserts for workshop storage of expanded collections

Safety Information

Personal Protective Equipment

Always wear appropriate safety glasses or goggles conforming to BS EN 166 to protect against swarf, metal fragments, and wood chips ejected during cutting. When cutting metals, wear heavy-duty work gloves during setup and holesaw removal, but never whilst the tool is running as gloves can catch in rotating components. Hearing protection conforming to HSE guidelines is advisable when using holesaws with powerful drills, particularly in enclosed spaces or when cutting metals.

Secure Workpieces Properly

Never hand-hold material being cut—always clamp workpieces securely to prevent rotation or movement. Holesaw cutting generates significant torque, particularly as the teeth break through the far side of the material, which can cause unsecured materials to spin violently, potentially causing serious injury. Use suitable clamps, vices, or workbenches to secure all workpieces before beginning cutting operations.

Power Tool Safety

Use power tools with side handles when cutting larger diameter holes (50mm+) to maintain control if the holesaw binds unexpectedly. Ensure your drill has sufficient power for the holesaw diameter—attempting to use oversized holesaws with underpowered tools can cause motor damage, overheating, or dangerous loss of control. Cordless tools should be fully charged for optimal performance and safety. On construction sites, use 110V tools via suitable transformers where required by site regulations.

Check for Hidden Hazards

Before cutting into walls, floors, or ceilings, always check for hidden electrical cables, water pipes, gas pipes, and structural elements using a suitable cable and pipe detector. Consult building plans and service drawings if available, and follow HSE guidance for work on existing structures. Striking hidden services can result in electrocution, flooding, gas leaks, or structural damage.

Hot Components

Holesaws become extremely hot during use, particularly when cutting metals and stainless steel. Allow adequate cooling time before touching components or attempting to remove material plugs. Use pliers or appropriate tools to handle hot holesaws and arbors. Never attempt to clear blockages or remove plugs whilst components are still hot.

Electrical Safety

Ensure mains-powered 240v tools are properly earthed via 13A plugs and suitable for the working environment. Inspect power cables and connections before each use for damage or wear. On construction sites, follow current UK electrical safety regulations and use residual current devices (RCDs) for additional protection. Cordless tools eliminate trailing cable hazards but ensure batteries are charged using approved chargers only.

Material-Specific Precautions

When cutting metals, use appropriate cutting speeds—excessive speed generates heat and reduces blade life, whilst insufficient speed can cause binding. Apply cutting lubricant regularly to reduce friction and heat buildup. When cutting materials like MDF or treated timber, ensure adequate ventilation or use dust extraction to prevent inhalation of harmful dusts, following COSHH regulations for workplace exposure.

Frequently Asked Questions

Can I use holesaws in a cordless drill or do I need a mains-powered tool?

Modern 18V cordless drills from quality brands like Makita, DeWalt, Milwaukee, and Bosch provide ample power for most holesaw applications up to around 65mm diameter in wood, plastics, and thin metals. For larger holesaws (100mm+), cutting through thick metals, or frequent intensive use, a corded 240v drill offers sustained power without battery limitations or charging delays. Ensure your cordless tool is set to drilling mode (not hammer mode), is fully charged, and has sufficient torque rating for the holesaw diameter you're using. Professional 18V tools typically handle up to 76mm holesaws in wood without difficulty.

How do I stop the holesaw from binding or jamming in the material?

Binding typically occurs when cutting too fast, when the pilot bit breaks through before the holesaw teeth fully engage, or when waste material accumulates inside the holesaw. Reduce pressure as you near breakthrough on the far side, and when cutting thick materials, periodically withdraw the holesaw whilst it's still rotating to clear accumulated waste. Using cutting lubricant or wax sticks when working with metals significantly reduces friction and binding. For wood thicker than 40mm, drilling from both sides creates a cleaner finish and prevents binding—drill until the pilot bit just penetrates, then complete the cut from the opposite side. Ensure your drill speed isn't too high, as excessive speed generates heat and increases binding likelihood.

What's the difference between a plumbers' and electricians' holesaw set?

Electricians' sets focus on smaller diameters typically ranging from 16mm to 76mm, suited to back boxes (25mm, 35mm), cable entry points (20mm), downlighter installations (64mm, 76mm), and electrical accessory mounting. Plumbers' sets include larger sizes often extending to 127mm or 152mm for waste pipes, soil stacks, and larger diameter pipework, whilst also including smaller sizes for copper pipe penetrations. If you work across multiple trades or tackle varied DIY projects, a general contractors' or multi-purpose set offers a broader size range covering most common applications from 16mm through to 76mm or larger.

How long should a quality bi-metal holesaw last?

With proper use and maintenance, professional bi-metal holesaws with 8% cobalt content from brands like Bosch Professional, Bahco, or Starrett can cut hundreds of holes before requiring replacement. Lifespan depends significantly on materials being cut—softwoods and plastics are least abrasive, mild steel and aluminium moderately abrasive, whilst materials like stainless steel, cast iron, or hardened steel dramatically reduce blade life. Using appropriate cutting speeds, clearing waste regularly, applying cutting lubricant when working with metals, and avoiding excessive pressure all extend blade life significantly. Premium professional brands typically outlast budget alternatives by considerable margins, often lasting three to five times longer in demanding applications, making them more economical despite higher initial cost.

Can I sharpen holesaws or are they disposable items?

Whilst technically possible to sharpen holesaw teeth, it's rarely economical for individual tradespeople or DIY users. The complex tooth geometry, variable pitch patterns, and case-hardened cutting edges require specialist grinding equipment and considerable expertise for proper sharpening. Professional sharpening services exist but are typically only worthwhile for very large diameter holesaws (100mm+) where replacement cost is substantial. Most tradespeople simply replace worn holesaws, particularly as individual replacement sizes are readily available from Tooled-Up.com at reasonable prices. Focus instead on maximising blade life through proper cutting technique, appropriate speeds for the material being cut, regular use of cutting lubricants for metals, and ensuring your drill provides adequate power without straining.