Tried using a 4-inch hole saw on a 2x4 and it did not go as planned

I was putting in some new wiring in my own house and needed a clean hole for a conduit. Grabbed my Milwaukee hole saw, figured a 4-inch would be fine on a 2x4. The thing grabbed so hard it nearly yanked the drill out of my hands and left a huge, splintered mess on the back side. I learned the hard way that you really need to back that cut with a scrap piece of wood, even on something that seems solid. Has anyone found a better trick for getting a clean through-hole in framing lumber without all the tear-out?

3 comments

3 Comments

piper_williams23d ago

My old DeWalt did the same thing on a 3-inch hole. Clamping a sacrificial board to the back is the only thing that works for me.

the_nina23d ago

Ever try a downcut bit to reduce that tear-out?

abby67523d ago

My buddy had that exact problem with his router last month. He was cutting some plywood and the back was a total mess. He tried a downcut bit after seeing it online and said it was a night and day difference. The top surface stayed super clean and the tear-out went into the waste piece. He did say you have to go a bit slower, but it fixed the issue completely. Honestly, watching his results made me want to buy one too.