In projects that demand our handy skills, hole saw size charts can be really useful. Why?
Because, in reality, hole saw sizes run a pretty big range and come in many types. Yep, more than you think!
However, hole saw size charts aren’t always straightforward or clear when you try to reference them.
In some cases, the chart(s) you need aren’t easily accessible or even available.
Lucky for you, I’ve laid out all the important charts in a simple and go-to fashion.
With little time and effort, I’ll help familiarize you with each of these charts.
My goal is to help you save time in the long run as you’ll be able to quickly reference these based on exactly what you’re doing.
Whether it’s running pipes for plumbing, electrical conduit, installing a lock in a new door, adding ceiling lights and more.
Overview of Charts and How to Read Them
First, let’s quickly identify the kind of project you need to work on.
Some common projects where I’ve used hole saws include the following.
1. Electrical work
Electrical projects need hole saws to cut holes in electrical boxes, wall panels, drywall, and conduits for wiring and cables.
2. Plumbing
In plumbing, hole saws cut holes for pipes and fittings of many, many sizes.
3. Carpentry and woodworking
For carpentry or woodwork, hole saws drill large holes in wood for pipes, cable runs, and other purposes.
4. Metalworking
Hole saws cut holes in sheet metal, metal pipe, and metal conduit for many applications.
5. HVAC
For HVAC work, you’d use hole saws, typically adjustable for convenience, to cut into duct or sheet metal.
6. Automotive
In automotive, you can use hole saws to make holes in metal or fiberglass panels for all kinds of modifications.
After identifying the materials you’ll work on, you can refer to a hole saw size chart to pick the proper tool.
Hole Saw Sizes by Project
I find it easier to check chart like below when it comes to sizes ranges available depending on what I’m working on.
| Project/Application | Material | Hole Saw Type | Imperial Sizes (in) | Metric Sizes (mm) |
|
Electrical Work |
Metal conduit, electrical boxes |
Bi-metal hole saw with carbide or HSS teeth edge |
¾ – 6 |
20 – 152 |
|
Plumbing |
PVC pipe |
Diamond-coated hole saw or carbide-tipped hole saw |
¾ – 6 |
19 – 152 |
|
Plumbing |
Metal pipe |
Bi-metal hole saw |
¾ – 6 |
20 – 152 |
|
Carpentry/Woodworking |
Wood |
Bi-metal or HSS hole saw |
9/16 – 6 |
14 – 152 |
|
Metalworking |
Sheet metal, metal pipe, metal conduit |
Bi-metal hole saw |
¾ – 6 |
20 – 152 |
|
HVAC |
Ductwork, HVAC equipment |
Bi-metal or carbide-tipped hole saw |
¾ – 6 |
20 – 152 |
|
Automotive |
Body panels |
Bi-metal hole saw |
¾ – 4 |
20 – 152 |
Now:
All you have to do is cross-reference your application to the hole saw type.
The recommendations are based on practical research.
For example, if you need to work on plumbing, and your pipes are PVC, a carbide-tipped hole saw is perfect.
Plumbing Hole Saw Chart
Next, refer to the chart for plumbing to see what hole saw sizes are available.
Basically, you want to make sure it matches the size of your pipe.
Use the following chart for your tungsten carbide-tipped hole saws:
| Pipe Diameter (in) | Pipe Size (mm) | Hole Saw Size (in) | Hole Saw Size (mm) |
|
½ |
13 |
7/8 |
22.2 |
|
¾ |
19 |
1-1/8 |
28.5 |
|
1 |
25 |
1-3/8 |
34.9 |
|
1¼ |
32 |
1-3/4 |
44.5 |
|
1½ |
38 |
2-1/8 |
54 |
|
2 |
51 |
2-5/8 |
67 |
|
2½ |
63 |
3-1/4 |
83 |
|
3 |
76 |
3-5/8 |
92 |
|
3½ |
89 |
4-1/8 |
105 |
|
4 |
102 |
4-1/2 |
114 |
Which means:
If your pipe is 2 inches (51 mm) in diameter, size your hole saw accordingly: 2-5/8 inches. You can convert to metric as needed: 67 mm.
Moving to a ¾-inch pipe means you need a 1-1/8-inch, or 28.5-mm, hole saw.
All the hole saw size charts cover both inches and millimeters.
Electrical Hole Saw Size Chart (SAE & Metric)
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| Hole Saw Size (in) | Hole Saw Size (mm) | Conduit/Pipe Size (in) | Conduit/Pipe Size (mm) |
|
7/8″ |
22.225 |
1/2″ EMT, Rigid |
12.7mm EMT, Rigid |
|
1″ |
25.4 |
3/4″ EMT, 1/2″ Rigid |
19.05mm EMT, 12.7mm Rigid |
|
1-1/8″ |
28.575 |
1″ EMT, 3/4″ Rigid |
25.4mm EMT, 19.05mm Rigid |
|
1-1/4″ |
31.75 |
1-1/4″ EMT, 1″ Rigid |
31.75mm EMT, 25.4mm Rigid |
|
1-3/8″ |
34.925 |
1-1/2″ EMT, 1-1/4″ Rigid |
38.1mm EMT, 31.75mm Rigid |
|
1-1/2″ |
38.1 |
2″ EMT, 1-1/2″ Rigid |
50.8mm EMT, 38.1mm Rigid |
|
1-3/4″ |
44.45 |
2-1/2″ EMT, 2″ Rigid |
63.5mm EMT, 50.8mm Rigid |
|
2″ |
50.8 |
3″ EMT, 2″ Rigid |
76.2mm EMT, 63.5mm Rigid |
|
2-1/4″ |
57.15 |
3-1/2″ EMT, 2-1/2″ Rigid |
88.9mm EMT, 76.2mm Rigid |
|
2-1/2″ |
63.5 |
4″ EMT, 3″ Rigid |
101.6mm EMT, 88.9mm Rigid |
|
2-5/8″ |
66.675 |
5″ EMT, 4″ Rigid |
127mm EMT, 101.6mm Rigid |
Pilot Bits Based on Hole Saw Sizes
While you might think you need to size a pilot bit the same way you size any drill bit, it’s not quite the same thing.
Using the proper pilot bit is essential for aligning the hole and supporting stability.
Most hole saws are matched with a pilot bit in design and size. But, if you need to, you can measure the hole where the pilot bit fits.
This will help you determine the size of the pilot bit needed. In some cases, a pilot bit may not be necessary.
Here’s a hole saw size chart for pilot bits:
| Hole Saw Diameter (in) | Hole Saw Diameter (mm) | Pilot Bit Diameter (in) | Pilot Bit Diameter (mm) |
|
3/4″ |
19.05mm |
1/4″ |
6.35mm |
|
1″ |
25.4mm |
1/4″ |
6.35mm |
|
1-1/8″ |
28.58mm |
1/4″ |
6.35mm |
|
1-1/4″ |
31.75mm |
1/4″ |
6.35mm |
|
1-3/8″ |
34.93mm |
1/4″ |
6.35mm |
|
1-1/2″ |
38.1mm |
1/4″ |
6.35mm |
|
1-3/4″ |
44.45mm |
1/4″ |
6.35mm |
|
2″ |
50.8mm |
1/4″ |
6.35mm |
|
2-1/8″ |
53.98mm |
1/4″ |
6.35mm |
|
2-1/4″ |
57.15mm |
1/4″ |
6.35mm |
|
2-1/2″ |
63.5mm |
3/8″ |
9.53mm |
|
2-5/8″ |
66.68mm |
3/8″ |
9.53mm |
|
2-3/4″ |
69.85mm |
3/8″ |
9.53mm |
|
3″ |
76.2mm |
3/8″ |
9.53mm |
|
3-1/8″ |
79.38mm |
3/8″ |
9.53mm |
|
3-1/4″ |
82.55mm |
3/8″ |
9.53mm |
|
3-1/2″ |
88.9mm |
7/16″ |
11.11mm |
|
3-5/8″ |
92.08mm |
7/16″ |
11.11mm |
|
4″ |
101.6mm |
7/16″ |
11.11mm |
|
4-1/8″ |
104.78mm |
7/16″ |
11.11mm |
|
4-1/4″ |
107.95mm |
7/16″ |
11.11mm |
|
4-3/8″ |
111.13mm |
7/16″ |
11.11mm |
|
4-1/2″ |
114.3mm |
7/16″ |
11.11mm |
|
4-3/4″ |
120.65mm |
7/16″ |
11.11mm |
|
5″ |
127mm |
7/16″ |
11.11mm |
|
5-1/8″ |
130.18mm |
7/16″ |
11.11mm |
|
5-1/4″ |
133.35mm |
7/16″ |
11.11mm |
|
5-3/8″ |
136.53mm |
7/16″ |
11.11mm |
|
5-1/2″ |
139.7mm |
7/16″ |
11.11mm |
|
5-3/4″ |
146.05mm |
7/16″ |
11.11mm |
|
6″ |
152.4mm |
7/16″ |
11.11mm |
Going back to the 2-inch PVC pipe we’re working with, we should use a ¼ inch or 6mm pilot bit.
Exact conversions from imperial to metric units show in many charts.
It’s normal to round to the nearest tenth when it makes sense.
Examples of Using a Chart
Let me walk you through a recent project I had for my bathroom pipes (metal).
I deemed Bosch bi-metal hole saws perfect for metal pipes and wood materials.
To slip my 2 ½-inch pipe through a wooden panel, I found on the chart that I needed a 3 ¼-inch hole saw size. A matching 3/8-inch pilot bit worked!
Keep metric conversions simple by using hole saw size charts!
That same 2 ½-inch pipe is also 63mm in diameter, which means I’d need an 83mm hole saw for the project.
For the pilot, 9.53mm (rounded to 10mm) would work perfectly!
Hole Saw Size Chart for Wooden Rods
On another note, let’s say you were working with wooden rods for furniture.
An HSS hole saw is great for this job, like Milwaukee’s selection.
Looking at this hole saw size chart, a 1-¼ inch rod (31.75mm) will require a hole saw with a size of 1-¾” (approx. 44mm).
| Rod Diameter | Inches | Millimeters | Hole Saw Size (inches) | Hole Saw Size (mm) |
|
1/8″ |
0.125″ |
3.175mm |
1/4″ |
6.35mm |
|
3/16″ |
0.1875″ |
4.763mm |
1/4″ |
6.35mm |
|
1/4″ |
0.25″ |
6.35mm |
3/8″ |
9.53mm |
|
5/16″ |
0.3125″ |
7.938mm |
1/2″ |
12.7mm |
|
3/8″ |
0.375″ |
9.525mm |
1/2″ |
12.7mm |
|
7/16″ |
0.4375″ |
11.113mm |
5/8″ |
15.88mm |
|
1/2″ |
0.5″ |
12.7mm |
3/4″ |
19.05mm |
|
5/8″ |
0.625″ |
15.875mm |
1″ |
25.4mm |
|
3/4″ |
0.75″ |
19.05mm |
1-1/8″ |
28.58mm |
|
7/8″ |
0.875″ |
22.225mm |
1-3/8″ |
34.93mm |
|
1″ |
1″ |
25.4mm |
1-1/2″ |
38.1mm |
|
1-1/4″ |
1.25″ |
31.75mm |
1-3/4″ |
44.45mm |
|
1-1/2″ |
1.5″ |
38.1mm |
2-1/4″ |
57.15mm |
|
1-3/4″ |
1.75″ |
44.45mm |
2-1/2″ |
63.5mm |
|
2″ |
2″ |
50.8mm |
3″ |
76.2mm |
This means that my pilot bit has to be ¼ in (or 6mm).
Note that pilot bits are more forgiving as long as you stay within a 1mm range.
Typically, you’d err on the smaller end for softer surfaces like softwood or drywall.
Using slightly bigger pilot bits for hardwood or thick metal is necessary.
FAQs
Q1: What Are the Parts of a Hole Saw Kit
- Mandrel/Arbor
- Hole Saw Blades
The black pieces in the figure are mandrels or arbors.
- Shaft
- Drive pins
- Collar (or Nut)
- Pilot bit
The choices of hole saw kits offering many sizes are usually in red or black colors.
Basically:
The mandrel is your middle-man for your hole saw and drill, so they must be compatible.
It’s common to have 4-pinned mandrels, but some mandrels have a quick-change mechanism.
Others may have a locking mechanism that secures the saw blade in place.
Q2: What Are Specialty Hole Saws?
Besides your typical hole saws, specialty hole saws are available for certain applications.
Some specialty hole saws include the following.
- Hole saws for recessed lighting: Cut holes for recessed lighting fixtures.
- Hole saws for door locks: Cut holes for door locksets and deadbolts.
- Hole saws for pipe and conduit: Cut holes for pipes and conduits to ensure a snug fit.
- Hole saws for speaker installation: Saw holes for speaker installation to ensure optimal sound quality.
Choosing the exact type of hole saw will depend on what you’re cutting and for what.
Watch this for a quick guide on adjustable hole saw kits:
In any project you may need a hole saw for, it’s super helpful to check hole saw size charts to help guide you the types and sizes to use.