"Joe AutoDrill" wrote in message
...
I've got a customer trying to drill a 1-1/16" diameter hole through a thin
(1/16") piece of wood/plastic composite material.

They can't really use a hole saw because the "plug" gets stuck in the
center of the tool and the process is automatic, running a few hundred
holes per shift and only stopping the drill machine to end a shift or
change a tool.

I know they make plug ejection tooling for metalworking hole saws (I sell
'em!) but they don't work with thin wood or plastic materials so I doubt
they will work with this.

I'm thinking there is either a special tool for this that ejects the plug
or that someone sells a unibit (stepped drill bit) off the shelf with the
1-1/16" diameter capability... But I can't find the daggone thing.

Anyone have any good ideas for me other than having custom tooling made or
modifying a standard hole saw? Maybe a source for that stepped drill bit
(looks like a Christmas tree).

Already tried McMaster and MSC but I'm sure there are other options out
there or that I may have missed it.


How about

http://www.pennstateind.com/store/FB1-116.html

or

http://www.mlcswoodworking.com/cgi-m...8&redirect=yes

or

http://www.amazon.com/Woodstock-D285.../dp/B0000DD32U

or