Make A Custom Hole Saw To Remove Stripped Screwscomments (5) July 1st, 2011 in Blogs
Video Length: 3:00
Produced by: John Ross, Edited by: Mike Dobsevage
If you need to pull a bent screw or busted nail from a piece of wood you want to save, you could dig it out with a cat's paw, but there's a better way.
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How to make a hole saw from a golf-club shank
This tip from comes from Don Stevenson from Woodland, Washington. He created a little narrow hole saw to dig fasteners out, made out of the shaft of a golf club. The hole saw leaves a clean hole that is easy to patch or plug.
Don starts by using a hack-saw to cut small kerfs in the end of a short section of an old golf club shaft, and then filing the kerfs to make small teeth. Lastly, Don uses a punch to flare the teeth out for a cleaner cut.
To use this mini hole saw, Don makes a guide block with a hole the same diameter as the golf club shaft, and clamps it over the screw so that the hole-saw has something to guide it into the work piece. Once the guide block is aligned over the screw, he clamps the work piece down, and drives the hole saw through the hole in the guide block. Once the screw is removed from the wood, he uses a long screwdriver to eject the plug from the end of the hole saw.
In testing Don's tip, we found that a chrome golf club shaft can be slippery, and it may be difficult to get a drill chuck to get a hold of it. Placing a wrap of masking tape on the end helps secure it in the chuck.
Another helpful tip: Cutting kerfs in the tubing is difficult. To make this task easier, make a feather clamp. Take a thin scrap of wood, drill a hole the same diameter of the tube, and cut a kerf down the center of the hole in line with the grain of the wood. Slide the tube into the hole in the scrap and clamp the wood into your vice. With even pressure all the way around the shaft, your vice should grip the tube well without crushing it.
posted in: Blogs, saws, drills and drivers, Better-Way
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