Milwaukee Thin Wall Hole Saw 3 PC set

Milwaukee has long been a trusted name in the tool industry, and when I had the chance to try out their Thin Wall Hole Saw 3 PC set (model number 49-22-4800), I was eager to see if it lived up to the brand's reputation. This set promises to make clean holes in plastics and thin gauge metals up to 1/8” thick, featuring a robust ¼” quick change hex shank that's compatible with impact drivers. It also boasts a thin wall 8 TPI design for faster cuts compared to standard bi-metal hole saws, a stop shoulder design to prevent over-drilling, and an ejection spring that automatically removes slugs. Here's my experience with this tool.

Initial Impressions

Out of the package, the Milwaukee Thin Wall Hole Saw set looks like a solid option for anyone needing to drill clean, precise holes in thin materials. The set includes three sizes: 7/8", 1-1/8", and 1-3/8". Each saw is built with a 1/4" quick change hex shank, making it easy to switch between sizes without any hassle. The clamshell packaging is sturdy, though I did wish it came in a more convenient carrying case for the price point.

Performance

I first put the set to the test on a stainless steel kitchen sink where I needed to add additional holes. Using the 1-3/8" saw, I was pleasantly surprised by how quickly and smoothly it cut through the metal. The pilot bit caught almost immediately, preventing any walking, and with a bit of WD-40 to keep things cool, the hole was clean with no burrs or sharp edges.

Next, I used the 7/8" saw to drill holes in an electrical panel for some conduit fittings. This is where I began to notice some issues. While the saw itself cut well, the pilot bit snapped after just a few holes. This was disappointing, especially since Milwaukee is known for their high-quality bits. The saws continued to perform admirably when I replaced the pilot bit with one of Milwaukee's Shockwave titanium bits, but the fact that the factory pilot bits broke so easily was a letdown.

Design Features

One of the standout features of this set is the stop shoulder design. This prevents over-drilling, protecting both the tool and the material you're working on. It's a thoughtful addition that can save you from making costly mistakes, especially in situations where over-drilling could damage sensitive components.

The ejection spring is another useful feature. It automatically removes slugs from the saw, which can be a real time-saver. During my tests, this worked flawlessly, and I never had to stop to manually remove a slug.

Durability

Durability is where this set has some serious drawbacks. Although the actual hole saws are robust and capable of cutting through thin metals and plastics without issue, the pilot bits are a weak link. They tend to break after minimal use, which can be incredibly frustrating, especially if you're in the middle of a job and don't have spare bits on hand.

Additionally, I noticed that the set screw, which holds the hole saw to the arbor, tends to strip out easily. This compromises the tool's ability to stay securely attached, leading to potential safety issues. It's a significant flaw that undermines the overall reliability of the set.

Usability

Despite the durability issues, the hole saws are user-friendly. The quick change hex shank makes it easy to switch between sizes, and the thin wall design ensures faster cuts compared to standard bi-metal hole saws. When used with a bit of lubricant like WD-40, the saws cut cleanly and efficiently, making them suitable for a variety of light-duty applications.

Recommendations

Would I recommend the Milwaukee Thin Wall Hole Saw 3 PC set? It’s a mixed bag. If you're an occasional user who needs to drill holes in thin materials sporadically, this set could serve you well. The saws themselves perform admirably, cutting clean and precise holes quickly. The stop shoulder design and ejection spring are handy features that enhance the tool's usability.

However, if you're a professional or someone who frequently needs to drill holes in thin metals or plastics, the durability issues cannot be overlooked. The pilot bits break far too easily, and the set screw problem can render the tool useless at the most inconvenient times. The fact that replacement pilot bits are hard to come by only exacerbates these issues.

In conclusion, while the Milwaukee Thin Wall Hole Saw set has some excellent features and performs well in ideal conditions, its durability issues make it hard to recommend for heavy or professional use. For occasional DIY projects or light-duty tasks, it could be a worthwhile addition to your tool collection, but professionals might want to look at more robust alternatives.