Ernie Leimkuhler wrote:
In article , Dave in MD
wrote:


I'd like to drill a 1 5/16" (1.3125 inch) hole in a 1 inch thick mild steel
bar. I only have a drill press in my shop. Is there a way to drill a hole
this big in a home shop, without a milling machine?

It has been suggested I try a HSS hole saw at low RPM (less than 400) with
plenty of cutting fluid.

It doesn't have to be pretty, and the jig I'm making doesn't require super
high precision.

Thanks,
Dave





You will kill a normal hole saw pretty fast with that thick of a bar.

What you want is a rotabroach.

www.hougen.com/

I use hole saws in this thick of material quite often - they last for
me. I'm not saying it's the fastest - just that it works & the saw lasts
as long as you use cutting oils.