Milwaukee Hole Dozer Bi-Metal Hole Saw

A few weeks ago, I had the opportunity to put the Milwaukee Hole Dozer Bi-Metal Hole Saw, model number 49-56-9659, through its paces on various projects. The Hole Dozer is designed with a 3.5 TPI tooth construction, promising durability and longevity for cutting through multiple materials. Armed with my cordless drill, I was eager to see if this hole saw lived up to its reputation.

Design and Build Quality

The Hole Dozer immediately impressed me with its robust build. The high-speed steel construction feels sturdy and well-engineered. The 7/8-inch diameter and 1-5/8-inch depth of cut make it versatile enough for a range of applications, from woodworking to metalworking. Its 3/8-inch hex shank is a practical feature, providing a secure fit in my drill's chuck and preventing slippage during use.

One notable design element is the set of access slots around the saw’s body. These slots are incredibly useful for removing plugs, which can often be a frustrating task with other hole saws. The visibility they afford also helps in ensuring precise placement, a feature I found particularly beneficial when working on more delicate projects.

Performance on Wood

I started by testing the Hole Dozer on a 2x4 piece of lumber. The saw bit into the wood with minimal effort, cutting through it like butter. The clean edges left behind were impressive, and there was hardly any chatter or vibration, which can often lead to inaccuracies. Over multiple uses, the teeth remained sharp, showing no immediate signs of wear.

Performance on Metal

Next, I turned my attention to metal. I had a 1-inch thick steel bar and a 7/16-inch thick mild steel base plate lined up for testing. With some cutting oil and a patient hand, the Hole Dozer performed admirably. It managed to cut through both pieces cleanly, and the teeth still felt sharp afterward. However, it’s worth noting that for thicker or harder metals, patience is key. Rushing the process could lead to premature dulling of the teeth.

Versatility and Additional Uses

The Hole Dozer isn’t just limited to creating holes. I found it handy for removing carbon buildup around spark plug holes, a task it handled perfectly. Its versatility extends beyond traditional hole saw functions, making it a valuable addition to my tool arsenal.

Durability Concerns

While my experience was largely positive, there are some durability concerns to address. Some users have reported issues with the threaded part of the saw being manufactured crooked, leading to imprecise holes. Although I didn’t encounter this issue personally, it’s something to be aware of. Additionally, the arbor bit has been noted to break easily under certain conditions. I didn’t face this problem during my testing, but it’s another potential drawback to consider.

Ease of Use

The Hole Dozer is user-friendly, especially with the design features like access slots and the secure hex shank. However, getting the leftover wood out of the barrel can be tricky initially. It takes a bit of practice, but once you get the hang of it, it becomes a non-issue.

Cutting in Different Materials

I also tested the Hole Dozer on thinner metals, like the stainless steel top of a kitchen sink and a mild steel BBQ cover. In both instances, the saw performed exceptionally well, cutting through quickly and leaving clean holes. For those working on projects that require precision and clean finishes, the Hole Dozer does not disappoint.

Maintenance and Longevity

Maintaining the Hole Dozer is straightforward. Regular cleaning and occasional use of cutting oil can extend its life significantly. However, some users have reported that the saw gets dull quickly and even rusts soon after first use. My saw showed no signs of rust, but it’s crucial to store it properly and keep it dry to avoid such issues.

Final Thoughts

The Milwaukee Hole Dozer Bi-Metal Hole Saw is a solid tool with a lot to offer. Its robust construction, versatility, and user-friendly features make it a valuable addition to any toolbox. While there are some concerns regarding durability, these can often be mitigated with proper use and maintenance.

Would I recommend the Hole Dozer? Yes, but with some reservations. If you’re looking for a reliable hole saw for occasional use across various materials, the Hole Dozer is a great choice. It performs well, is easy to use, and offers features that enhance its functionality. However, if you require a tool for heavy-duty, frequent metal cutting, you might want to consider other options or be prepared to replace it more frequently.

In conclusion, the Milwaukee Hole Dozer Bi-Metal Hole Saw stands out for its versatility and ease of use. It’s a reliable tool for a range of applications, provided you’re mindful of its limitations and take care to maintain it properly.