Hole saws

[brian]

first, either remove the saw from the arbor, or don't attach it. drilling the pilot with the saw on will almost every time take teeth off the saw and or break/bend the pilot as you break through with the pilot hole.

now with the 1/4" hole through, select your saw and attach. cutting fluid, oil, grease whatever is strongly suggested it just makes things work better. i have used soldering paste once in a jam.

now when you start the saw hole, gently lean the drill to one side, the smaller the saw the size the more you can lean.
what you do not want to do is try and drill the saw hole flat. once you have a decent crescent shaped cut on one side, gently and smoothly lean the drill back the other way to start the hole on the other side.
now that you have a circle cut started in your piece the pilot is not doing much. oncei get to this point i often remove the pilot bit all together.
the best approach is to keep rocking back and forth, cut on one side for a spell, then rock back the other way. all your trying to do is keep some of the teeth off the material. juicing it the entire time is key to making sure the hole saw will be good for more than one hole.
breaking through with saw leaning will not cause problems.
do not force the cut, let the saw do the work. with a fresh saw(of decent quality) you shouldn't have to lean on the drill that hard.

 

[kcustom73]

Update

I ended up using the following hole saw from Dewalt to cut the hole in my bumper:Drilling Accessories: Impact Ready Hole Saws | DEWALT Tools. I was worried for nothing as this hole saw cut thru the 3/16" plate like it was butter.