How to Use a 1-3/16" Carbide Hole Saw on Sheet Metal
By Drill Hog® | Published: 2026-10-30
Category: How-to Guides
Learn the correct way to cut clean 1-3/16" holes in sheet metal with a TCT tungsten hole saw, including setup, technique, and common mistakes to avoid.
Quick Answer
Use a 1-3/16" carbide hole saw with a 3/8" shank in a drill running at moderate speed, let the pilot bit center the cut, and let the built-in spring eject the plug for clean, burr-free holes.
Why Carbide Tipped Matters for Sheet Metal
Tungsten carbide tipped (TCT) hole saws handle the abrasive nature of sheet metal far better than standard high-speed steel. The carbide teeth stay sharp longer and cut cleaner, reducing the need for deburring.
The 1-3/16" size is a common choice for electrical and HVAC work, where you need to run conduit or cables through metal panels. Its compact diameter makes it easier to control than larger hole saws.
Understanding the Built-In Features
A built-in flange prevents over-drilling, which is especially important when you're cutting through thin sheet metal and don't want to damage what's behind it. The pilot bit starts and centers the hole, while the spring automatically ejects the plug after the cut.
The tri-flat shank prevents the cutter from spinning in the chuck, a common issue with round-shank hole saws. Make sure your drill chuck is at least 3/8" to accommodate the shank.
Step-by-Step Cutting Process
- Secure the work piece: Clamp the sheet metal firmly to a stable work surface. If it can move or vibrate, the hole saw will grab and produce an uneven cut. Use a backing board to prevent deformation. Always clamp, never hold the sheet by hand.
- Mark the hole center and pilot: Use a center punch to create a small dimple at the exact hole location. This gives the pilot bit a positive start and prevents it from wandering across the surface. A dimple is your best insurance against a crooked hole.
- Insert the hole saw into the drill: Make sure the drill is off, then insert the 3/8" shank into the chuck and tighten securely. The tri-flat shank prevents spinning in the chuck, but only if the chuck is fully tightened. Double-check the chuck tightness before starting.
- Set the drill speed: Use a moderate speed, around 500-800 RPM for sheet metal. Too fast can overheat the carbide teeth and cause premature wear. If your drill has variable speed, start slow and increase as needed. If the metal turns blue, you're going too fast.
- Start the cut with the pilot bit: Place the pilot bit in the dimple and start the drill. Let the pilot bit drill through the metal first. This centers the hole saw and keeps it from skating across the surface. Don't force the hole saw; let the pilot bit do the initial work.
- Cut with steady, light pressure: Once the pilot bit has penetrated, apply steady, light pressure to the drill. Let the carbide teeth do the cutting. The built-in flange will stop the cutter from going too deep, preventing damage to the back side. Avoid excessive pressure; it can cause the teeth to chip.
- Eject the plug and finish: After the cut is complete, the built-in spring will automatically eject the plug. If it doesn't, remove the hole saw from the drill and push the plug out. Check the hole for burrs; the carbide teeth should leave a clean edge, but a light deburring tool can smooth any roughness. Inspect the plug and hole for any signs of uneven cutting.
Product Facts
- 1-3/16" Carbide Hole Saw Electrician Cutters TcT Tungsten Sheet Metal Holesaw: Features a 3/8" shank that fits 3/8" or larger drills, a pilot bit for centering, and a built-in spring for plug ejection. These features work together to keep the cutter stable and make the process nearly hands-free after the pilot bit engages.
1-3/16" Carbide Hole Saw Electrician Cutters TcT Tungsten Sheet Metal Holesaw
