Milwaukee Hole Lock Installation Hole Saw Kit

As a seasoned DIYer and a long-time advocate of Milwaukee tools, I had high expectations when I got my hands on the Milwaukee Hole Lock Installation Hole Saw Kit (Model 49-22-4073). This kit promised to be a comprehensive solution for door lock installations, boasting features like a durable hole saw design, a 3.5 TPI tooth configuration, and a Lifetime Tooth Break Warranty. However, my experience was a mix of highs and lows—highlighting some serious design flaws alongside commendable attributes.

Initial Impressions and Setup

Out of the box, the kit appears robust. The hole saws themselves are well-built and have a reassuring heft to them. The inclusion of access slots for easy slug removal and increased pilot visibility seemed like thoughtful touches. The thermoset coating, designed to reduce friction, and the compatibility with cordless tools were additional plus points.

Setting up the jig was straightforward. The instructions were clear, and the adjustable backset feature made it easy to switch between 2-3/8" and 2-3/4". The jig clamps securely to the door, or so it seems initially. The rubber bumpers are meant to provide a snug grip without damaging the door's surface.

Performance on Wood and Metal

My first attempt was on a wooden door, which is the more forgiving of the materials listed. The hole saws cut through the wood efficiently. However, a significant issue arose when switching between the larger and smaller hole saws. The arbor, which should allow for easy switching, tends to get stuck—tightened by the very action of drilling. This was frustrating and time-consuming to resolve, highlighting a design flaw that shouldn't be present in a product at this price point.

On metal doors, the kit's performance was less impressive. While the 3.5 TPI tooth design is theoretically suitable for metal, in practice, the hole saws struggled. The saws caught on the metal, causing the drill to kick and the jig to shift slightly. This led to misaligned holes and a less-than-professional finish. The jig's flex and slipping rubber bumpers were particularly problematic here, compromising precision.

Enlarge Existing Holes

One area where this kit does shine is in enlarging existing holes. Using additional clamps, as some users have suggested, helps stabilize the jig. This method worked well for me, particularly on a metal door, where I needed to enlarge a 1-5/8" hole to 2-1/8". After securing the jig more firmly, I completed the task with relative ease. However, it's worth noting that this workaround should not be necessary for a premium product.

Design Flaws and Usability

Several design flaws became apparent during use. The single-point clamp system does not provide the necessary stability for precise drilling, especially on metal surfaces. The switch for adjusting the backset is prone to slipping, which can ruin the alignment mid-task. Additionally, the hole saws themselves, while durable, tend to get clogged easily, especially the 1" saw. This requires frequent clearing, adding to the overall time and effort needed for what should be straightforward tasks.

Another critical issue is the material of the jig itself. Being made of plastic, it is prone to wear and tear from the hole saws. During my use, the hole saws shaved off pieces of the plastic jig, which raises concerns about its long-term durability. For a tool that claims to offer lifetime reliability, this is a significant drawback.

Overall Experience

The Milwaukee Hole Lock Installation Hole Saw Kit has its merits. When the conditions are ideal—such as on a clean, straight wooden door and with the jig firmly clamped—it can perform quite well. The design intentions are good, and features like the thermoset coating and access slots are genuinely helpful.

However, the kit falls short in several crucial areas. The issues with the arbor and the jig's stability are not minor inconveniences; they are significant flaws that hinder the tool's overall effectiveness and user experience. For a product positioned as a premium solution, these shortcomings are disappointing.

Recommendations

Would I recommend the Milwaukee Hole Lock Installation Hole Saw Kit? Unfortunately, I would not. While it has some positive aspects, the critical design flaws and inconsistent performance make it unreliable for professional use. The arbor's tendency to seize, the jig's instability, and the problematic material quality are issues that need addressing.

For those who only occasionally need to install locks and are prepared to deal with its quirks, this kit might be passable. However, for more frequent or professional use, I would suggest looking at alternatives that offer better stability and ease of use, even if it means spending a bit more or opting for a different brand.

In conclusion, while the Milwaukee Hole Lock Installation Hole Saw Kit has the potential to be a great tool, it requires significant improvements to meet the high standards typically associated with Milwaukee products. Until then, I would recommend exploring other options for your door lock installation needs.