How to Make a Clean Hole with 1 1/8" Dill Bit?

[DonRotolo]

Originally Posted by EricH

I'm going to disagree on that, Don. I'm willing to bet that with the right extra equipment, I could nail a 1.125" diameter hole with a hand drill, or two. I've done something similar before, though with a smaller hole. (I've hand-drilled one using a step drill, too. That was "fun".)

I'd be using some core drills, an egg cup or two, a drill block and clamps, and a bunch of bushings, ending with a reamer. For the larger holes, I'd use a much slower drill. It's definitely possible, but it'll take time. (I tried to hunt stuff like that up on McMaster yesterday, but no dice. Might have to try another source.)

Eric, I have no doubt you could DO it. My point was that it's not SAFE to use a hand-held drill for such a large hole using the OP's twist drill setup. Core drills react differently to snags than twist drills.

That also doesn't mean I have never done it. But I know the dangers and addressed them. Case in point: I still have all my limbs, and in proper working order.

[colin340]

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https://washingtondc.craigslist.org/...359358574.html

[JamesCH95]

I would vote step drill, and then maybe reaming to the final size.

I've always had good results using step drills, in a hand-drill or otherwise.