How to Drill a Hole Bigger than Your Drill Bit?

Most of the DIYers have to make holes while making different items or during repairing something. If you want to make a big hole, then you will require a big drill bit.

But what if you have a small drill bit and want to make a hole bigger than the bit? In such a situation, you have to drill in a certain way. In this guide, we will tell you how to drill a hole bigger than your drill bit without making the surrounding surface of the hole messy.

Also Read: DW1361 Vs DW1342: Dewalt Titanium Drill Bit Set

How to Drill a Hole Bigger than Your Drill Bit?

A drill bit makes a well-shaped hole by spinning. For making an accurate hole, the drill bit has to rotate evenly and for that, the center of the drill bit has to register in the right place.

When you make a hole bigger than the drill bit, then the bit wanders around inside the hole. There are chances that the holes end up being messy when making a big hole with a smaller drill bit.

So, you have to work carefully. It is better to purchase a big drill bit to make a bigger hole. But if you don’t have one, then you should follow the below few steps.

Step 1: First, drill a small hole by squeezing the trigger of the drill. After making a hole and when the drill bit is still rotating, slowly make circularmovements gently around the hole to enlarge it. Keep moving the drill until you get the desired size.

The other way to drill bigger holes is by using a guide. Take a piece of hardwood and make a hole by using the guide.You can put the drill bit through the hole size you want and start drilling. The drill guide helps in keeping the bit inside the hole and prevents it from spinning out.

The edges of the guide are quite solid, so the bit won’t wander around. A hole can also be enlarged in this method.

Step 2: Next, you can use a tapered reamer. First, drill a hole with the drill bit you have, and enlarge the hole of the wood, plastic, or metal with the help of a reamer.

All you have to do is insert the reamer into the hole and start twisting to make a bigger hole. The reamer should be twisted continuously until you get the desired hole size. Using a reamer might not give you a clean hole. The sides won’t be straight.

Step 3: To make larger holes for a new handle or knob, you can use a pilot bit. In case when a hole already exists, it becomes hard to enlarge or make a bigger hole than the existing one as there is no wood for the pilot bit to bite one around. 

In this circumstance, you can add a thin piece of luan or plywood on each side of the work surface. Clamp the pieces securely and start drilling. The scrap pieces will keep the pilot bit stable while cutting the work-piece, as a result, the surface of the work-piece won’t be ruined or scratched.

Step 4: Lastly, you can also use step drill bits to make a big hole. They are quite good and do a fair job for certain applications.

So, in these above methods, you can make a big hole with a smaller drill bit.

How to Enlarge an Existing Hole in Metal?

It is difficult to make a large hole in metal with a smaller drill bit. So, the solution is to use a tool called a reamer. The tool cannot make a hole, it only helps in enlarging an existing hole.

So, in case you don’t have a bigger drill bit, drill the metal with the existing drill bit and enlarge it by using a reamer. Below we have explained the steps of how to use a reamer to make a big hole.

1. Start by fixing the work-piece securely so that it remains stable while drilling.

2. Next, drill a hole in the metal which you want to enlarge with a reamer.

3. Then get an appropriately sized reamer according to the hole size you want.

4. Make sure to increase the hole in small increments and not in one operation.

5. Then the next step is to fit the reamer to the drive tool.

6. Place the reamer inside the hole and start cutting by applying adequate pressure.

7. The cut is complete when the reamer reaches the widest point.

8. After completing the cut, withdraw the reamer.

Wrapping It Up

You need to have the right tools to make the cuts you want. It might be a little difficult to make a hole bigger than the drill bit, but there are some methods in which you can successfully pull it off without ruining the work-piece.

You can choose any one method which is easier for you. I hope this article on how to make a hole bigger than the drill bit will help you in the future when repairing or replacing something.