Holesaws

About Holesaws

Holesaws are essential cutting tools designed to create perfectly round holes in a wide variety of materials including wood, metal, plastic, and composite materials. Unlike standard drill bits that remove material from the entire diameter, holesaws feature a cylindrical saw blade with cutting teeth around the edge, allowing you to cut larger diameter holes efficiently whilst removing a circular core. This makes them indispensable for installing pipes, cables, lighting fixtures, ventilation systems, and door furniture across numerous trades.

Our comprehensive range of holesaws includes professional-grade bi-metal hole saws from leading brands such as Bosch and Bahco, offering exceptional durability and cutting performance. Whether you need individual hole saws for specific diameter requirements or complete holesaw sets for maximum versatility, we stock solutions for every application. Specialist options include carbide-tipped multi-construction holesaws for demanding materials, electricians' sets with the most common cable installation sizes, and plumbers' kits featuring larger diameters for pipe work.

The holesaws we supply range from compact sizes for electrical outlet boxes through to large diameter models for soil pipes and ventilation ducting. Many sets include mandrels, pilot bits, and multiple saw sizes in convenient carry cases, providing everything you need for professional installations. Our selection covers both metric and imperial sizing to suit UK trade requirements, with hole saws suitable for use with standard power drills, impact drivers, and drill presses.

Jargon Buster

• Bi-Metal Construction: Holesaws manufactured with a high-speed steel (HSS) cutting edge welded to a flexible spring steel body, providing both durability and resistance to tooth breakage. This design combines the hardness needed for cutting with flexibility to prevent cracking.
• Mandrel: The threaded shaft and pilot drill bit assembly that holds the holesaw securely in your drill chuck. The mandrel centres the saw and provides the driving force, with the pilot bit preventing drift when starting the cut.
• Variable Pitch Teeth: A tooth pattern where the spacing between teeth varies around the saw's circumference. This design reduces vibration, provides smoother cutting, and helps prevent the saw from binding in the material.
• Arbor: Another term for the mandrel, particularly common in professional circles. Quick-change arbors allow rapid swapping between different diameter holesaws without tools.
• Carbide Grit: Extremely hard cutting particles bonded to the saw edge, ideal for abrasive materials like tiles, glass, brick, and composite materials where standard teeth would quickly dull.
• Kerf: The width of material removed by the saw's cutting teeth. A narrower kerf requires less power and cuts faster, whilst a wider kerf provides better chip clearance in demanding applications.

Who Uses Holesaws?

Holesaws are versatile tools used across numerous trades and applications:

• Electricians and sparkies - Installing back boxes, cable entry points, downlighters, and conduit penetrations
• Plumbers - Creating clearance holes for waste pipes, radiator pipework, and shower installations
• Carpenters and joiners - Fitting door locks, handles, curtain poles, and creating cable routing in joinery
• HVAC engineers - Cutting ventilation grilles, extractor fan outlets, and ducting penetrations
• Kitchen and bathroom fitters - Installing taps, waste outlets, appliance connections, and service penetrations
• General builders - Site work requiring penetrations through various materials for services and fixtures
• Maintenance engineers - Facilities management, retrofit installations, and building modifications
• DIY enthusiasts - Home improvement projects including lighting upgrades, storage solutions, and fixture installations

How to Choose the Right Holesaws

Material Compatibility: Select holesaws designed for your typical workpiece materials. Bi-metal holesaws handle wood, metal, and plastic effectively, whilst carbide-tipped or diamond-grit models are essential for tiles, masonry, and composite materials. Check the manufacturer's specifications for maximum material thickness and hardness ratings.

Diameter Requirements: Consider whether you need specific sizes or would benefit from a comprehensive set. Electricians typically require 16-25mm for back boxes and cable entries, whilst plumbers often need 32-110mm for pipework. Multi-piece sets offer better value for tradespeople working across varied applications.

Build Quality: Professional bi-metal construction from brands like Bosch Professional and Bahco ensures longevity under demanding site conditions. Variable pitch teeth reduce vibration and extend blade life. Look for electron beam welded tooth connections that prevent premature tooth loss.

Mandrel Type: Quick-change arbors significantly speed up work when using multiple diameters. Some sets include multiple mandrels for different size ranges, whilst universal systems allow one arbor to fit various saw sizes. Ensure compatibility with your existing equipment if purchasing individual components.

Set Configuration: Trade-specific sets bundle the most useful sizes for particular professions. Electricians' sets typically include smaller diameters, plumbers' sets focus on larger pipe clearances, and general contractors' sets provide broad coverage. Consider a storage case for organisation and protection on site.

Depth of Cut: Standard holesaws typically cut 38-40mm deep, suitable for most applications. Deeper cutting models are available for thicker materials or when working through studwork with insulation.

Popular Accessories

• Replacement Mandrels and Arbors: Spare or upgraded quick-change systems for faster work and compatibility with different holesaw brands
• Pilot Drill Bits: Replacement centre bits for worn or damaged mandrel assemblies, ensuring accurate starting points
• Holesaw Storage Cases: Protective carry cases keeping your collection organised and preventing damage to cutting edges
• Extension Arbors: Extended mandrels for cutting through deeper materials or reaching recessed areas
• Plug Ejection Springs: Assists with removing cut cores from deep holesaws, particularly useful in metal
• Cutting Lubricants and Pastes: Specialist compounds extending blade life and improving cutting performance in metal
• Power Drills and Combi Drills: Suitable power tools with adequate torque for driving larger diameter holesaws effectively
• Drill Stands and Presses: Providing stability and perpendicular accuracy for precision installations

Safety Information

Personal Protective Equipment: Always wear safety glasses or goggles to protect against flying debris and metal shavings. Hearing protection is advisable when cutting metal or working in enclosed spaces. Wear appropriate work gloves when handling holesaws, but never whilst operating the drill as gloves can catch in rotating components.

Secure Workpiece Clamping: Always firmly secure materials before cutting. Holesaws can grab unexpectedly, particularly during breakthrough, causing workpieces to spin dangerously. Use clamps, vices, or purpose-built jigs rather than attempting to hand-hold materials.

Electrical Safety: Before drilling into walls or ceilings, use a cable and pipe detector to identify hidden services. Cutting into live electrical cables presents serious electrocution risks. Ensure your power tools are PAT tested and comply with UK safety standards.

Tool Operation: Start slowly to establish the pilot hole before increasing speed. Excessive pressure reduces cutting efficiency and risks tool breakage. Let the saw do the work, applying steady moderate pressure. When breakthrough is imminent, reduce pressure to maintain control and prevent the drill from being pulled through violently.

Hot Surfaces: Holesaws and cut material become extremely hot during operation, especially in metal. Allow adequate cooling time before touching or handling cut cores. The HSE recommends appropriate precautions when working with hot materials or tools.

Plug Removal: Use proper plug ejection tools rather than fingers to remove cores from holesaws. Cut edges are extremely sharp and can cause serious lacerations. Dispose of metal swarf carefully to prevent injury to yourself and others on site.

Frequently Asked Questions

What's the difference between bi-metal and carbide holesaws?

Bi-metal holesaws feature high-speed steel teeth welded to a spring steel body, ideal for wood, metal, and plastic. They're the professional standard for general trade work offering excellent value and longevity. Carbide-tipped or carbide-grit holesaws have extremely hard cutting surfaces designed for abrasive materials like tiles, brick, fibre cement, and composite materials that would quickly destroy standard teeth. Carbide models cost more but are essential for multi-material construction work.

Why does my holesaw keep binding or jamming?

Binding typically occurs from excessive feed pressure, insufficient drill speed, or accumulated swarf blocking the gullets between teeth. Withdraw the saw periodically to clear debris, especially when cutting metal or deep holes. Ensure your drill operates at the recommended speed—generally 300-500 RPM for larger holesaws. Using cutting lubricant when working with metal significantly reduces friction and binding. If the pilot bit isn't sharp or properly centred, it can also cause the saw to wander and bind.

Can I use the same holesaw for wood and metal?

Quality bi-metal holesaws from brands like Bosch Professional and Bahco are designed to cut both wood and metal effectively. However, cutting abrasive materials or very hard metals will dull the teeth more quickly than wood alone. For optimal blade life, some tradespeople maintain separate sets for different materials. Always clean the saw thoroughly when switching between materials to prevent cross-contamination, particularly when moving from treated timber to metal.

How do I remove the cut plug from inside the holesaw?

Most holesaws have slots in the side wall allowing you to insert a screwdriver to lever out the plug. Some professional models include ejection springs that automatically push cores out. When plugs are particularly stubborn, drilling a small hole through the waste material allows you to push it out from behind. Never force your fingers into a holesaw—the teeth and cut edges are extremely sharp. Purpose-made plug ejection tools are available for frequent users.

What size holesaws do I need for common electrical work?

UK electricians typically require 16mm for single gang back boxes, 25mm for double gang boxes, and 20-22mm for standard cable entries. For downlighters, sizes vary by fitting but 65-90mm covers most LED and GU10 installations. A comprehensive electricians' holesaw set usually includes 16mm, 20mm, 25mm, 32mm, and sometimes larger sizes for conduit work. Check specific fixture requirements before cutting, as tolerances for electrical accessories are typically tight, and oversized holes create installation difficulties and compromise aesthetics.