What types of hole saws are there out there that are good and within the small home workshop budget. I am after drill upto 50mm holes in RHS and SHS 3mm thick.
there are bimetallic hole cutter, the likes of starret etc , then there are the mag drills that use rotabroach cutters which can be adapted to use in a normal drill, just be aware that id be using a pillar drill, had the hole cutter jam and flung the drill round nearly snapping wrists, either way nice and slow with some cutting fluid of oil, going fast just burns out the teeth
As above tried all except Irwin and about as good as each other.
Bimetals the way to go, lasts longer, cuts better.
I did go over to the Bosch ones 2 years ago, last even longer than above for similar price but with one advantage that they are true quick release. No need to line up the locking pin of Starret types, theyre loose which means massive oversize hole or cuts to one side.
In aluminium 6082 5/8" thick used to run up to 2" dia around 900rpm because it was a pain dropping the belted speed.
Even with an easy change gearbox 310rpm is a little quick, 240rpm to 280rpm about right by feel and higher than Starret recommend.
Steels need slower speeds.
I bought a job lot of Lenox Speed Slot holesaws and they are amazing! They are incredibly thin, cut and track brilliantly so the holes are very accurate. I haven't had them long so I can't tell how well they will last but so far they don't see to have lost there edge.
They even have a stepped slot to eject the disk out. http://youtu.be/2JvwYXtnpOw
They came from a guy at the J24 market in Bridgwater who sells surplus engineering bits on a Saturday.
15 Lenox holesaws in various sizes up to 90mm with two arbours was £30.
He normally has a good supply of Dormer drills at decent prices as well.