DeWalt 3 in. Bi-Metal Hole Saw

A 3-inch opening is a common ask—recessed lights, bath fans, dryer vents, grommets—and that’s exactly why I picked up this DeWalt 3-inch hole saw. After a week of mixed-material tasks in the shop and on a small remodel, I came away with a clear picture of where this cutter shines and where you’ll want to plan around its limits.

What it is and how it’s built

This is a bi‑metal, variable-pitch (4/5 TPI) 3-inch hole saw with a maximum cutting depth of 1-3/4 inches. The deeper cup matters: it clears modern 2-by lumber (nominal 1-1/2 inches) in a single pass. The body includes a large continuous side slot for ejecting plugs and clearing chips. It takes a 5/8-18 threaded arbor—standard for larger diameters—but the arbor is not included.

At 0.65 lb, the saw has enough mass to run smoothly without feeling ponderous on a hand drill. Fit and finish are what I expect from DeWalt: even tooth set, clean weld, and consistent paint. Mine arrived true with no wobble.

Setup, arbors, and compatibility

Plan to source a matching 5/8-18 arbor with a pilot bit. That generally means a 1/2-inch chuck drill or drill press. The pilot bit seated firmly with no runout, and the threads mated cleanly—no binding or backlash. If you only have a compact 3/8-inch drill, this size hole saw isn’t a good match anyway, mostly due to torque and speed control.

One spec that jumps out is the 120 RPM maximum. That’s conservative and frankly appropriate for a 3-inch cutter in metals. Many cordless drills bottom out at 300–450 RPM in low gear. I ran it comfortably on a right-angle drill and a corded low-speed drill; on a typical 18V drill/driver, I had to feather the trigger and let the clutch and side handle do their jobs. If you have a drill press, hitting 100–150 RPM makes life easy, especially on steel.

Performance in wood

• 2x SPF studs: The deeper cup cleared in one pass as advertised. I marked a centerline, started square, and let the saw do the work. The tooth geometry evacuated chips cleanly; plunging 1/2 inch, backing out to clear chips, then finishing the cut produced a clean kerf with minimal burning. Exit tear-out was modest when I didn’t use a backer; with a backer board, it was nearly invisible.
• Plywood and OSB: Variable pitch helps reduce chatter on plywood veneers. OSB produced more dust than chips (as usual), but the cut remained controlled. The plug released easily through the side slot—two taps with a mallet and a twist with pliers freed it.

I’d call the cut speed medium-fast for a bi-metal saw this size. Carbide-tipped alternatives are quicker in wood, but this one offers more versatility across materials.

Performance in plastics

• Schedule 40 PVC and ABS: Smooth, no chipping on the rim. Slow speed and light feed pressure mattered; too aggressive and you’ll melt the plastic. I used a backer block to support the exit and kept the chips cleared. The plug ejected without drama thanks to the continuous slot.

Performance in metal

• 18-gauge mild steel HVAC plenum: With cutting oil and about 100–120 RPM, the saw tracked neatly and produced a round hole with minimal burr. The pilot bit didn’t wander.
• 1/8-inch aluminum plate: Smooth cutting at 150 RPM with a spritz of lubricant. Chips cleared well. I let the saw cool between passes to keep the teeth crisp.
• Stainless? I tested a short pass in a scrap of thin 304. It cut, but slowly, and heat rose quickly. It’s possible with patience and proper fluid, but I wouldn’t buy this primarily for stainless.

In metal, tooth integrity held up. No chipped teeth after several holes, just a light polish at the cutting edges—normal wear for bi-metal.

Chip evacuation and plug ejection

The slot design is genuinely helpful. On deeper plugs in wood, I could get a screwdriver in to pry while tapping the side of the saw. Compared to older designs with smaller windows, this cleared faster and kept me working. In metal, the side slot doubled as a chip dump—tilting the drill slightly during retraction allowed chips to tumble out rather than pack.

Control, vibration, and heat

The saw runs smoothly for a 3-inch diameter. Variable pitch noticeably reduces harmonic chatter, especially on plywood and thin sheet. I still recommend:
- Use a side handle and brace your wrist.
- Start square with light pressure until the teeth establish a kerf.
- Step-cut: drill 1/4–1/2 inch, retract to clear chips, re-lube if you’re in metal, then continue.

At or below 120 RPM, heat stayed controlled. Above that, you’ll burn wood and dull teeth in metal. This speed requirement is the tool’s biggest practical constraint—many users will need a drill with a truly low low-speed.

Durability and tooth life

After a dozen holes spread across 2x SPF, plywood, ABS, 18-gauge steel, and aluminum, the tooth line still cuts cleanly. The bi-metal composition favors longevity over raw speed; it forgives the occasional dry cut in wood and the accidental moment of too much feed pressure without losing teeth. Like all bi-metal saws, hard impacts (nails, screws) are the main enemy. I purposely hit one coated deck screw in a test stud; it dinged a couple teeth but didn’t stop the cut. I dressed the burr with a diamond card and kept going.

Practical details and value

• Weight: 0.65 lb is a nice balance—enough inertia for smoothness, not so heavy that it tires your wrist.
• Max depth: 1-3/4 inches really does enable one-pass 2x cuts, which is a time saver overhead.
• Country of origin is listed as USA (subject to change). My sample had clean QC.
• No arbor in the box, so factor that into cost. If you already own a 5/8-18 arbor, you’re set.

Compared to a carbide-tipped 3-inch cutter, this is slower in wood but far more economical and versatile for occasional metal. Compared to other bi-metal options (Lenox, Milwaukee), performance is in the same class. The standout here is the generous ejection slot and the conservative speed rating that protects the teeth if you follow it.

Tips for best results

• Use a low-speed drill or drill press. Target 80–120 RPM for steel, 100–200 for aluminum, 150–300 for wood and plastics, staying within the stated max.
• Clamp the work and support the exit side to prevent blowout.
• Score a shallow groove by angling the saw to the line before going full contact for a cleaner start on thin sheet.
• Lube for metals; clear chips often. In wood, back out periodically to avoid heat glaze.
• Keep a pair of pliers handy to twist out stubborn plugs via the side slot.

Pros

• Deeper cup clears 2x lumber in one pass
• Effective chip evacuation and large plug ejection slot
• Smooth, low-chatter cutting thanks to variable pitch
• Durable bi-metal teeth across wood, plastics, and common metals
• Solid build with true-running cup

Cons

• 120 RPM max requires a drill with real low-speed control
• Arbor not included; requires 5/8-18 threaded arbor (larger, pricier)
• Not ideal for frequent stainless work or super-fast wood production

Recommendation

I recommend this 3-inch hole saw for remodelers, electricians, HVAC techs, and DIYers who need a dependable, multi-material cutter and have access to a low-speed drill or drill press. It excels at one-pass holes in 2x lumber, handles plastics cleanly, and cuts mild steel and aluminum with the right technique. The generous ejection slot and stable, low-chatter performance make day-to-day use straightforward.

If your workflow demands high-speed production in wood or frequent stainless cuts, a carbide-tipped saw or a specialized cutter will serve you better. For everyone else—especially those who value clean holes, predictable control, and tooth longevity—this DeWalt hole saw is a smart, durable choice.