Milwaukee 7/8" Thin Wall Hole Saw

As an avid user of various hole saws, I was quite intrigued to try out the Milwaukee 7/8" Thin Wall Hole Saw. This tool, designed specifically for impact drivers, promises faster cuts and a host of other features that seem to cater to both professionals and DIY enthusiasts. Here’s my detailed take on how it fared during my usage.

Initial Impressions

Right out of the package, the Milwaukee 7/8" Thin Wall Hole Saw boasts a robust design. The quick change hex shank is a notable feature, allowing for easy attachment to impact drivers, which is highly convenient for quick jobs. The hole saw itself has an 8 TPI (teeth per inch) design, which Milwaukee claims will cut faster than standard bi-metal hole saws. Additionally, the stop shoulder design and the ejection spring are features that aim to prevent over-drilling and facilitate easy removal of slugs.

Performance

When it comes to performance, the Milwaukee hole saw delivers mixed results. Initially, I used it to cut through a thin sheet of metal, and it performed admirably. The hole saw cut cleanly and efficiently, and the stop shoulder prevented me from drilling too deep, which is a thoughtful design feature. The ejection spring worked well in this scenario, promptly removing the cut metal plug.

However, as I continued to use the tool, some issues began to surface. The pilot bit, which is essential for starting the hole, proved to be somewhat fragile. On one occasion, the pilot bit broke early during use. Fortunately, the pilot hole it managed to create was enough to guide the hole saw, but I had to switch to using a regular drill bit to create the pilot hole for subsequent cuts. This workaround is less than ideal and adds unnecessary steps to the process.

Durability and Longevity

Durability is where the Milwaukee 7/8" Thin Wall Hole Saw shows its vulnerabilities. While the tool performs exceptionally well out of the gate, its lifespan is shorter than I had hoped. After several uses, particularly in harder materials like aluminum and steel, the teeth began to wear down, and the cutting efficiency decreased noticeably. The ejection spring also lost its effectiveness over time, often requiring manual intervention to remove the cut plugs.

The impact shank, another critical component, showed signs of weakness after several uses. During one of my projects, the shank snapped off, rendering the tool unusable until replaced. Fishing out the broken shank from my impact driver was a tedious task that I could have done without.

Practicality and Usability

In terms of practicality, the hole saw is quite handy for quick jobs and thin materials. It’s particularly well-suited for creating knockouts in electrical boxes or HVAC equipment. The quick-change feature is genuinely useful, allowing me to switch between tasks without fumbling with additional tools.

However, for more demanding applications, the tool falls short. The fragility of the pilot bit and the eventual wear on the cutting teeth limit its use for heavy-duty tasks. Additionally, the lack of readily available replacement parts, such as the pilot bit, adds to the frustration. Having to hunt down specific components or resort to temporary fixes undermines the overall convenience the tool aims to offer.

Versatility

One of the standout features of this hole saw is its versatility. It works efficiently on a range of materials including plastics, thin gauge metals, and even fiberglass. I found it particularly useful for making clean cuts in plastic boxes and thin metal sheets, where precision and a smooth finish are crucial. The tool's ability to handle different materials makes it a valuable addition to any toolbox, provided the limitations in durability are kept in mind.

Edge Retention and Maintenance

Edge retention is another critical aspect of any cutting tool, and the Milwaukee hole saw does show some promise here. Initially, the teeth are sharp and cut through materials with ease. However, maintaining this sharpness requires careful use. High speeds and prolonged use in hard materials can quickly degrade the cutting edge. Lubrication helps to some extent, but the tool’s longevity is inherently limited by its thin wall design, which sacrifices some durability for speed.

Maintenance is relatively straightforward. Keeping the teeth clean and free of debris ensures smoother cuts and prolongs the tool’s life. However, the ejection spring, which is supposed to aid in maintenance by removing cut plugs, often becomes less effective over time, necessitating manual removal of stuck material.

Value for Money

Considering the price point, the Milwaukee 7/8" Thin Wall Hole Saw offers decent value for money, especially for light to medium-duty tasks. It’s more affordable than some of the high-end carbide hole saws, making it an attractive option for those on a budget. However, the need for frequent replacements due to wear and tear might offset the initial savings in the long run.

Final Thoughts

Would I recommend the Milwaukee 7/8" Thin Wall Hole Saw? It depends. For those needing a quick, efficient tool for light to medium-duty tasks, particularly in thin materials, this hole saw performs well and offers good value. Its quick-change feature and initial sharpness make it a useful tool for electricians, HVAC technicians, and DIY enthusiasts working on small projects.

However, for more demanding tasks or heavy-duty applications, the durability concerns and the fragility of the pilot bit make it less appealing. The tool’s performance diminishes significantly with prolonged use, and the lack of readily available replacement parts adds to the inconvenience.

In summary, the Milwaukee 7/8" Thin Wall Hole Saw is a handy tool with some notable strengths and a few critical weaknesses. It’s a solid choice for specific applications but falls short of being a reliable all-around performer.