Whenever I used a hole saw, I’d encounter a problem. Right off the bat, the teeth would clog with sawdust and the saw would heat up and start to burn the wood. After the smoke cleared, I’d find the hole was a mess. But recently a friend let me in on his “secret” technique for using a hole saw.
The idea is pretty simple. First, use the hole saw to lightly score the surface of the wood and outline the hole. Next drill a ¾″ clearance hole all the way through the workpiece along the inside edge of the scored “circle.” When you resume cutting with the hole saw, the clearance hole will allow the sawdust to escape the teeth. And if the saw does clog, it won’t won’t heat up and burn the wood.
Online Editor, Woodsmith