They can't really use a hole saw because the "plug" gets stuck in the center of the tool and the process is automatic, running a few hundred holes per shift and only stopping the drill machine to end a shift or change a tool.
I know they make plug ejection tooling for metalworking hole saws (I sell 'em!) but they don't work with thin wood or plastic materials so I doubt they will work with this.
I'm thinking there is either a special tool for this that ejects the plug or that someone sells a unibit (stepped drill bit) off the shelf with the 1-1/16" diameter capability... But I can't find the daggone thing.
Anyone have any good ideas for me other than having custom tooling made or modifying a standard hole saw? Maybe a source for that stepped drill bit (looks like a Christmas tree).
Already tried McMaster and MSC but I'm sure there are other options out there or that I may have missed it.
Regards, Joe Agro, Jr. (800) 871-5022 01.908.542.0244 Automatic / Pneumatic Drills: http://www.AutoDrill.com Multiple Spindle Drills: http://www.Multi-Drill.com Production Tapping: http://Production-Tapping-Equipment.com / Flagship Site: http://www.Drill-N-Tap.com VIDEOS: