Holesaw Sets

About Holesaw Sets

Holesaw sets are essential toolkit additions for tradespeople and DIY enthusiasts who regularly need to cut clean, accurate holes through various materials including wood, metal, plastic, and composite boards. 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.

A quality holesaw set will include 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 for enhanced durability and cutting performance across multiple materials, whilst specialist sets are available for specific trades or applications. Electricians' holesaw sets focus on smaller diameters suitable for cable entry and accessory installation, plumbers' sets include larger sizes for pipe work, and dedicated downlighting sets feature the exact sizes needed for fitting recessed spotlights.

At Tooled Up, we stock holesaw sets ranging from budget-friendly options perfect for occasional DIY use through to professional contractors' kits designed to withstand the rigours of daily site work. Whether you're installing kitchen and bathroom fittings, running electrical installations, or tackling general construction and joinery tasks, investing in a comprehensive holesaw set delivers better value than buying individual components whilst ensuring you always have the right size to hand.

Jargon Buster

• Bi-Metal Construction: Holesaws made 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.
• 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.
• 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.
• 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.
• Quick Change System: A tool-free arbor system allowing rapid switching between different holesaw sizes without requiring spanners or additional tools. Bosch's Power Change system is a popular example favoured by professionals for saving time on site.
• Kerf: The width of material removed by the holesaw teeth during cutting. A narrower kerf removes less material, requiring less power and producing less waste, though extremely narrow kerfs may be more prone to binding in thick materials.

Who Uses Holesaw Sets?

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

• Electricians and Sparkies: Installing back boxes, cable entry points, downlighters, and electrical accessories in walls, ceilings, and panels
• Plumbers and Heating Engineers: Creating pipework entry points through joists, walls, and floors for copper pipes, waste pipes, and radiator feeds
• Carpenters and Joiners: Door furniture installation, cable management holes, and general woodworking applications
• Kitchen and Bathroom Fitters: Tap holes in worktops, waste outlet holes, and accessory mounting in various materials
• General Builders and Contractors: Wide range of site applications requiring clean holes through construction materials
• HVAC Engineers: Ductwork penetrations and ventilation grille installations
• Shop Fitters and Glaziers: Display unit installations and hardware mounting
• Maintenance Engineers: Repair work and modifications requiring access holes in industrial and commercial settings
• DIY Enthusiasts: Home improvement projects including lighting installation, plumbing upgrades, 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 65mm, ideal for back boxes and downlighters, whilst plumbers' sets include larger diameters up to 152mm for waste pipes. Multi-purpose sets offer broader size ranges suitable for general contractors and DIY users.

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, and ceramics, whilst carbide-tipped versions tackle abrasive materials like fibreglass and cement board.

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. Occasional users may find excellent value in mid-range options from Faithfull or Draper.

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, whilst traditional threaded arbors are universally compatible and easily replaced if damaged.

Storage and Organisation: A good quality case keeps your set organised, protects the cutting edges during transport, and makes it easy to identify missing sizes. Look for clearly labelled storage with secure closures suitable for site conditions.

Set Composition: Consider how many pieces you genuinely need. Larger 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 14-16 piece collection better suits your requirements.

Popular Accessories

• Individual Replacement Holesaws: Replace worn or damaged sizes from your set without buying an entire new kit
• Additional Arbors: Spare arbors and extended-reach versions for cutting through thicker materials
• Pilot Drill Bits: Replacement pilot bits in various lengths and diameters
• Holesaw Accessories Kit: Adaptors, extensions, and conversion accessories for increased versatility
• Cutting Lubricants and Wax Sticks: Extend blade life and improve cutting performance in metals
• Plug Ejection Springs: Help remove material plugs stuck inside holesaws after cutting
• Magnetic Holesaw Arbors: Magnetic retention prevents holesaws loosening during operation
• Power Tool Accessories: Side handles, depth stops, and drill stands for improved control and accuracy
• Holesaw Storage Solutions: Aftermarket organisers and storage racks for workshop use

Safety Information

Personal Protective Equipment: Always wear appropriate safety glasses or goggles to protect against swarf and material fragments. When cutting metals, wear heavy-duty gloves during setup and removal but never whilst the tool is running. Hearing protection is advisable when using holesaws with powerful drills, particularly in enclosed spaces.

Secure Workpieces Properly: Never hand-hold material being cut—always clamp workpieces securely to prevent rotation or movement. Holesaw cutting generates significant torque that can cause materials to spin violently if not properly secured, potentially causing serious injury.

Power Tool Safety: Use power tools with side handles when cutting larger diameter holes to maintain control if the holesaw binds. Ensure your drill has sufficient power for the holesaw diameter—attempting to use oversized holesaws with underpowered tools can cause motor damage or loss of control. Cordless tools should be fully charged for optimal performance and safety.

Check for Hidden Hazards: Before cutting into walls, floors, or ceilings, always check for hidden cables, pipes, and structural elements using a suitable detector. Consult building plans if available and follow HSE guidelines for work on existing structures.

Hot Components: Holesaws become extremely hot during use, particularly when cutting metals. Allow adequate cooling time before touching or attempting to remove material plugs. Use pliers or appropriate tools to handle hot components.

Electrical Safety: Ensure power tools are properly earthed and suitable for the working environment. On construction sites, use 110V tools via a suitable transformer where required. Inspect cables and connections before use, following current UK electrical safety regulations.

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, and Milwaukee provide ample power for most holesaw applications up to around 65mm diameter. For larger holesaws (100mm+) or frequent use in tough materials, a corded drill offers sustained power without battery limitations. Ensure your cordless tool is set to drilling mode (not hammer mode) and is fully charged for best results.

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

Binding typically occurs when cutting too fast or when the pilot bit breaks through before the holesaw teeth fully engage. Reduce pressure as you near breakthrough, and when cutting thick materials, periodically withdraw the holesaw to clear waste. Using cutting lubricant when working with metals significantly reduces friction and binding. For wood, drilling from both sides creates a cleaner finish and prevents binding.

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

Electricians' sets focus on smaller diameters (typically 16mm-65mm) suited to back boxes, cable entry points, and downlighter installations. Plumbers' sets include larger sizes (often up to 152mm) for waste pipes, soil stacks, and larger diameter pipework. If you work across multiple trades, a general contractors' or multi-purpose set offers a broader size range covering most common applications.

How long should a quality bi-metal holesaw last?

With proper use and maintenance, professional bi-metal holesaws can cut hundreds of holes. Lifespan depends on materials being cut—wood is less abrasive than metals, whilst materials like stainless steel or hardened steel dramatically reduce blade life. Using appropriate speeds, clearing waste regularly, and applying cutting lubricant when working with metals all extend blade life significantly. Professional brands like Bosch, Bahco, and Starrett typically outlast budget alternatives by considerable margins.

Can I sharpen holesaws or are they disposable?

Whilst technically possible to sharpen holesaw teeth, it's rarely economical for individual users. The complex tooth geometry and hardened cutting edges require specialist equipment for proper sharpening. Most tradespeople simply replace worn holesaws, particularly as individual replacement sizes are readily available. Focus instead on maximising blade life through proper technique, appropriate speeds, and using cutting lubricants where applicable.