[asid61]

Originally Posted by Ryan Dognaux

A little cutting oil and not trying to go too fast made this work just fine on 1/8" aluminum 2" x 1" box.

From a quick caliper check before I left, I read 1.125-1.127". So maybe not enough for a true press fit but I was pretty pleased. Our chuck also vibrates a little more than I'd like; with a better drill press you could probably hit even better numbers.

The spring sort of helped - but we did do thru holes on 2" x 1" aluminum box, and was able to easily get the discs out of the hole saw.

Probably not the ideal way to do these but if you're in a pinch or if you need a low cost option, I think it works pretty well.

That's really good tolerances. Like really really good. I don't think regular shelled insert holesaws can come close to that tolerance. We might consider buying one of those for causal use.