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  hole saw is correct ....
  Posted by: pilotwingz on Jun-20-13 7:59 AM (EST)

-- Last Updated: Jun-20-13 7:22 PM EST --

...... 1-1/2" hole saw for a 1-1/2" o.s. dia. tube .

As you said already , you are in control of the pressure . One suggestion , cut in from both sides . Don't cut clean through from just one side cause blow out may happen .

Another way to help prevent blow out if cutting through from just one side is to ... use a backer up tight against the side , something like a piece of 2x6 held tight either by hand (someone elses) , or preferably clamped .

Also some hole saws have finer teeth than others , finer is better for your job .

I wouldn't use a larger saw than the tube . If the fit is really snug try a fine rat tail to ease it a bit .

I wouldn't cut too close to an edge cause I think there's a chance that a crack over the hole could develop in time .

ps., ... a variable speed drill would be best cause you can keep the rpm lower and be more precision on thin materials that way .

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