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Thread: Modifying a hole saw arbor to make a double hole saw

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    Supporting Member Frank S's Avatar
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    Modifying a hole saw arbor to make a double hole saw

    TO do this make take making several special tools
    I started off by grinding a holding flat on an extended length 1/4" drill bit. So I could mount the arbor on it upside down, the reason why will become apparent after a few more tools are made
    Modifying a hole saw arbor to make a double hole saw-img_20220413_191836hs.jpg
    Next I reamed a 3/8 flat washer to fir over the 7/16" 20 thread
    Modifying a hole saw arbor to make a double hole saw-img_20220413_193030hs.jpg
    Next I put the large diameter hole saw on the arbor and used 2 5/8" hardened washers as shims. The only reason I used hardened washers were they are consistent in thickness and had just the correct stack up thickness, then I placed the reamed 3/8 washer over these. This would allow the small diameter hole saw to serve as the locking nut to hold the large hole saw
    Modifying a hole saw arbor to make a double hole saw-img_20220413_195110hs.jpg
    Next I had to make a thread insert because the 3/4" Dewalt hole saw has 1/2-20 thread and the arbor has 7/16- 20 thread
    to make the thread insert I used .032" soft mechanics safety wire.
    I chucked a 3/8 bolt and the wire in one of my lathes then with the back gear engaged I ran the lathe in reverse to make a spring out of the wire
    Modifying a hole saw arbor to make a double hole saw-img_20220413_194510ti.jpg
    Modifying a hole saw arbor to make a double hole saw-img_20220413_194614ti.jpg
    I then installed the wire spring in the small hole saw
    Modifying a hole saw arbor to make a double hole saw-img_20220413_195037ti.jpg
    Then tightened the hole saw on the arbor making a double hole saw for making washers out of brass shim stock
    Modifying a hole saw arbor to make a double hole saw-img_20220413_195316hs.jpg
    This shows the assembly from the rear
    Modifying a hole saw arbor to make a double hole saw-img_20220413_195321hs.jpg

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  2. The Following 6 Users Say Thank You to Frank S For This Useful Post:

    baja (Apr 15, 2022), durrelltn (Apr 14, 2022), Jon (Apr 15, 2022), NortonDommi (Apr 17, 2022), nova_robotics (Apr 14, 2022), Toolmaker51 (Apr 14, 2022)

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    Thanks Frank S! We've added your Double Hole Saw to our Metalworking category,
    as well as to your builder page: Frank S's Homemade Tools. Your receipt:




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