should I drill or should I saw?

[Dee Rogers]

I'm working on tweaking our gear puzzle.This puzzle has many 1/4 holes in it and up till now we have used a high powered punch that makes a great hole but leaves tear out of the paper on the top surface (not the bottom) of the puzzle. I have thought about drilling, and cutting the holes with my saw. Cutting the holes with my saw will take forever, so does anyone know of a drill bit that will not tear out the paper on top or the wood on the bottom?
How do you avoid tear out?
Thanks.
Dee

[Scrolling Days]

Hi, Dee.....I went through this problem pretty extensively in the past when trying to develop a technique to countersink the gems I like to place in some of my puzzles. I ultimately settled on a technique which does not use drill bits, but in your case, if you are trying to drill all the way through, you have to use a bit. Unfortunately, I don't think there is a bit out there which will not leave some tear-out of the paper. In the very best situation, there will be some mushrooming of the paper near the drill hole. I tried many types of bits, and even considered trying to use tiny Forstner bits (which I ultimately learned did not come in the small size I needed).

In the end, I think paper disruption is inevitable when trying to drill. Your best bet might just be to drill a tiny pilot, then scrollsaw a larger hole. Bummer, I know.......if you find a bit which works, though, let us know!

[Bill Wilson]

Perhaps a 1/4" Forstner bit would work.

[wood-n-things]

I would try a 1/4" forstner as well.

[Scrolling Days]

If I recall when I was experimenting, the Forstner bits definitely had the best results.....the problem is they are hard to get under 1/4".

If you don't need to go smaller, I agree that the Forstner will be the best bit to go with......I think even those left a bit of fraying however. I'm sure, as always, much will have to do with the type of paper being used as well.

[Dee Rogers]

Thank you Shawn, Bill and Mike, I will try the Forstner bit!

[Forester21]

to keep the tear out on the bottom to a minimum, attach another layer underneath your wood. It can be cardboard even - doesn't have to be wood.
T

[Dee Rogers]

So I went shopping last night and got the Forstner drill bit, tried it out ,Fantastic! It worked great.
Thank you