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Originally Posted by Cory
You should investigate using 1/16 wall tube if you frequently have this problem. It's going to be stronger than a heavily pocketed out 1/8" wall tube.
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Totally agree - we had already purchased a lot of 1/8" thickness material and didn't have 1/16th yet. We later swapped our elevator railing to 1/16" thickness with no holes and loved it.
We pretty much used all 1/8th 2" x 1" on our drive train though and used the hole saws to take some material out. It's just too convenient for us to go any thinner on the drive since we can press bearings in as needed and not really need to worry about adding extra material.
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Originally Posted by Sanddrag
That Harbor Freight set is pretty inexpensive. Does it work well? For anyone looking for a high-quality hole saw set, I've been very happy with this set.
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The answer, as with everything from Harbor Freight, is it depends on the application. We cheesed some thin plate material this year with them and we also cut holes in 1/8" thick aluminum with them. With the thicker material I'd highly recommend vigorous use of cutting fluid. After about 100 holes over two robots this year we killed one of them, which isn't really surprising. For the price they do a decent job.
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Originally Posted by Michael Hill
Does it work well? How many more files will we need to buy to get rid of the burrs?
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That's when you break out your cheap angle grinder that you also purchased at Harbor Freight
http://www.harborfreight.com/4-12-in...der-69645.html - obviously doesn't work too well for the interior burrs but we weren't too concerned with those. Can hit those with your Dremel tool as needed.