George E. Cawthon wrote:
Martin wrote:
I'm trying to make a special gasket out high density foam rubber. Actually
I'm using a kid's 4oz practice hockey puck as the blank. It's 1" thick and I
need to make a 1" hole in it's center. Does anyone know of type of bit or
other type of cutter that would make a clean cut. The common bits and step
bits just rip it up.

I haven't seen one of these practice pucks so I have no idea how stiff
the foam is but:
1. The first thing that comes to mind is one of those Greenlee chassis
punches. It was a die for cutting large holes in an aluminum chassis. I
see they're still sold:
http://www.radiodaze.com/tooltool.htm
Maybe your local TV/electronics shop has one you can borrow for 2
minutes. Brand new it might do the job.
2. I also think the above poster might be right about the reversed hole
saw. You might also be able to compress the puck between two sheets of
ply and hole saw through the sandwich.
3. Grind the teeth off an old 1" hold saw to make a cylindrical knife.
Use a drill press as a mini press to cut straight thru the foam. No
rotation or perhaps a back and forth stroke. Actually I remember doing
this with my drill press using some thin wall tubing on some HD polyu.
Richard