Holey Holey Holey or best easiest way to profile Ring Fighters

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Holey Holey Holey or best easiest way to profile Ring Fighters!
So in the back of my cranium there is a few "Ring Fighter" designs that have been floating around forever
Hesitation on execution is making the 1" hole using only a drill press or drill press and a Foredom
Suggestions... Other than waterjet for now Will be using 5/32- 3/16ths D2 or AEB L
 
A bimetal holesaw works very well. You need to clamp it very securely. I'd do a test hole first to get the feel of it. It makes a mess if it slips and chatters, but I can show you pictures of great results.

ETA: Here's one in a thick pommel.
PXL_20210529_164048962~2.jpg
 
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Saw a Tungsten coated one your thoughts? Have had bad luck with smaller Carbide bits being brittle.
Assuming a large size and the right speed and feed would overcome that issue...
 
A 1" carbide tipped hole saw costs around $10. Check Amazon. You can get a set of 10 for around $60. The pilot drill is often tungsten coated.
 
I just bought the pack of 5 or 6 different sizes from Lowes for about $15. It works well enough in annealed steel.

ETA I think I have the Lenox, but looking at them online just now it seems the price has gone up...
 
I picked up a 2MT to 3/4" Weldon adapter with through coolant feed for my drill press a while back, which lets me use annular cutters. The DP is a British Kerry Super 8 with backgear for low speed operation (54 RPM minimum speed) and copes pretty well with the Annular cutters, though I also have access to a Magnetic drill at work, which copes better.

The cheap Carbide holesaws also work surprisingly well. The "better" ones from Starrett or HMT do seem better than the cheapies off ebay/amazon, but not by a huge margin, IME, on non-blade steels including 316 SS and annealed O1 Ground Flat Stock. They tend to produce a much cleaner hole than bimetal holesaws (again IME). I'd suggest a practice-run, or several, on something cheap before attacking an expensive chunk of blade steel. I've not tried them on anything more exotic than annealed O1, so can't offer specific advice.

A useful method if you have a less-than-optimal drilling setup is to holesaw a hole through a bit of scrap material, then clamp the scrap to the item you actually want the hole in and use the hole in the scrap to guide the cutter with the pilot drill removed. I tend to use this method mostly when I'm on site and can't use a rigid setup, or when I need a disc of something without the pilot hole in the middle. It works with both bimetal and Carbide holesaws. Mostly, I use MDF scrap, but for the Carbide-tooth holesaws a bit of steel is probably better.

Another potentially-useful trick is to drill the pilot hole (usually 1/4") and to fit a bit of drillrod into the holesaw instead of the pilot drill. This tends to limit the amount of wander, particularly with bimetal holesaws. Once these start to chatter and cut not-quite-true, the flutes of the pilot drill can chew into the sides of the pilot hole and enlarge it, allowing the holesaw to wander further. The drillrod can't enlarge the pilot hole, so limits the wander somewhat.
 
I know its not what you asked for (drill press advice) but a small hobby lathe with a four jaw chuck would add so much flexibility to your designs and manufacturing process, you could accurately vary the hole sizes, chamfer or radius the edges on both sides, cut additional concentric designs of various profiles on the faces, things you just cannot do with a water jet cut hole.
Maybee a little bit down the line but worth keeping in the back pocket for later.
 
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