I’ve never run 1″ conduit before and have a 1 1/4″ hole saw that doesn’t quite do it, should I get a 1 1/2″ or is 1 3/8″ a better fit? I need to run through a 2X4 block and then into a disconnect where there are no punchouts where I need to go.
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You can run the pipe thru wood in whatever size hole fits, but 1-3/8" sounds better to me for the reason that you could get a plumber's self-feeding bit in that size, which is way easier to use than a hole saw. On the knockout, you'll be happier using a Greenlee punch to go thru the metal.... but all of this doesn't matter if you're just doing this once. If so, get the fitting for the conduit and measure the size of the hole you need for that, and buy one hole saw. Drilling the steel box with it will definitely take the edge off your hole saw teeth.
I have those red hole saws that all fit onto a common arbor, and they're bi-metal so work pretty good. Thanks for the input.