Hole Saw Difficulties

[Russer72]

Hey All!

I am having a brutal time mitering some tubes at the moment. I am trying to notch a Columbus Zona Megatube (biconical type)down tube and the hole saw keeps snagging on its way through, leaving a VERY poor cut. I am using a Starrett hole saw but I am thinking it might be too coarse (6/8 tooth profile). Any suggestions and advice would be appreciated!

Cheers,
Russer72

[steve garro]

Hey All!

I am having a brutal time mitering some tubes at the moment. I am trying to notch a Columbus Zona Megatube (biconical type)down tube and the hole saw keeps snagging on its way through, leaving a VERY poor cut. I am using a Starrett hole saw but I am thinking it might be too coarse (6/8 tooth profile). Any suggestions and advice would be appreciated!

Cheers,
Russer72

I'd bet it's your setup as I've used all those things together no sweat.

Zone is super workable unlike a bunch of other truly hard steels

- Garro.

[Jamie Medeiros]

Are you removing the chip from the inside when it bottoms out in the hole saw? I always stop mid way to clip the chip off with a pair of tin snips so it doesn't bind in the saw. Also clamp as close to the cut as you can and make sure everything is extremely well clamped down and rigid. Finally, experiment with feeds and speeds and a little coolant or cutting oil. Starrett saws should be ok for this. I do like the Rockhard 10 tpi saws that Missouri Precision sells ( Missouri Precision Tools, Inc. ) I feel they are less prone to snagging. One last thing, try to do your down tube / head tube cut in one try. I find that if I try to trim a down tube it wants to snag about 3/4 the way through the tube when the tooth angle and the tube wall reach a certain geometry. On the initial cut the part being cut off seems to help support the tube during this phase.

[Eric Estlund]

What's driving the hole saw and what is holding the tube? I agree- feeds and speeds, as well as consistent work holding, are going to make all the difference.