Best Way to Enlarge a Metal Hole with an Angle Grinder?

I have a neat trick for this! You can actually thread two hole saws onto one arbor. Use the smaller one as a guide for the larger one that matches the size you need. This way, you’ll have a better starting point for making a clean cut!

Using a die grinder might be a better option since it's easier to control than an angle grinder. It’ll give you a chance to make the adjustments more accurately. Just keep an eye on your control to prevent any mishaps!

While a die grinder is good, it may be challenging to get a perfectly even hole and could take a while. Using cut-off wheels can be tricky too—they're sharp, and if you don’t handle them well, you could end up injured. Another option is to use a hole saw; just clamp some scrap wood behind the metal for stabilization. Drill a center hole first to guide the saw, then start cutting. Just keep in mind that with a cheaper hole saw, you might only get a few uses out of it before it dulls.