Using a hole saw on foam board

[jdubbya]

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Using a hole saw on foam board?

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I need to drill several 3.5 inch holes in some 1 inch thick foam board. As there will be pvc pipe going through the holes, I need them to be as close to perfectly round as possible. Would a hole saw work or would this be a diastrous mess? If not, what other suggestions can you folks offer, Appreciate any advice!

[malibuman]

It should'nt be no problem. Now if it was the foam that's made up of tiny little beads, then it might be messing. To be honest, I've drilled everything with my hole saw.

[slightlymad]

Just take your time and if possible use a press

[jdubbya]

Sounds good. It's worth a try. Thanks!

[Mr Unpleasant]

If you have any trouble try using a longer bit in the mandrel and a block of wood beneath.

[Lynn]

Use a saw that has the mjost teeth as possible..... I used a large drill bit to drill a 1" hole worked well. But my bit was a litle smaller than the 1" and then when done the hole was 1"...
I did 'chew up" the foam a little. So, take it slow and hold the drill as steady as possible.

[UnOrthodOx]

Hmm.

We actually did this at work, but we were saving the circles, not trying to preserve the holes.

Anyway, I can work, provided it's a very rigid foam. If it's nice and soft, it'll be a mess.

[Dark Hawke]

keep the RPM's as high as possible and go slow

[Bilbo]

I use a portable drill press for stuff like this. Keeps the drill at exactly 90º to the foam.

[creepy crawler]

You can also do it by hand with no drill set the hole saw where you need it and start turning it slow and maybe even backwards .... like stated before if rigid works much better if balled type styrofoam good luck!!!!