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Drilling 1" holes in thin plastic


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#21 Offline brianhershey - Posted October 3 2018 - 3:19 PM

brianhershey

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You should make a video of a hole saw drilling clean, crack free holes into thin polystyrene.

 

 

No video but here is the third attempt of using 1" hole saw (with a pilot bit) in 1mm polystyrene. The first two cracked simply making a pilot hole with a small standard bit preparing for the hole saw. I was using a hand drill, 500rpm, not clamped, held down on a piece of wood. Results would be better clamped, I would assume. 

 

The small hole in the picture is using a step bit, the large hole using a 1" hole saw. Both a bit rough but easily smoothed with sandpaper.

 

I've had 1mm polystyrene easily crack using a step bit as well.

 

So my conclusion is to have BOTH a step bit and hole saw available, clamp well and use minimum pressure while drilling.

 

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