In my experience, the Blu-Mol type holesaws work really well... if you
get the speed and down feed correct.
I don't even pretend to be a machinist, but you need to turn the big
hole saws much slower than most electric hand drills turn, and you need to
push down very hard. There are so many teeth in contact with the work, that
it's almost impossible to get enough downward force by hand.
Setting up your mill at something like 150 - 200 rpm (if you can) and
using plenty of lube and down feed... I *think* you could make those holes
very easily, quickly, and without a lot of noise. Unfortunately, my milling
head only goes down to 380 rpm and none of my drill presses go below 300
rpm... but that's my own problem. lol
There are some basic rpm guidelines here (I'm sure there are others
online)
http://www.buy-power-tools.com/dewheavdutho.html where the maximum rpm for a
2-1/2 hole saw is listed at only 135 rpm.
Just a thought. It sounds like you have the right tool... possibly not
the right implementation.
David


"Jesse L Zufall" wrote in message
...
I have a 4x7.7 I-beam I need to drill a series of 1 3/8, 2" and 2 1/2"
holes
through the web. What is the most productive means to accomplish this. I
have tried the BLU-MOL hole cutters but the noise is incredible and it is
a
slow process. Need to cut the noise and increase the speed. I see where
Travers has circle cutters ..( 57-071-001) was wondering if anyone has
ever
tried these and how the hold up.
I do have access to an small lathe and mill and am open to other
alternatives.

Jesse L Zufall
Silt Co


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Its kind of like bacon and eggs.....The chicken is involved, the pig is
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