Peter E. Nuskey, a Southampton, Pa.-based mechanical consultant and custom machining veteran, wrote that he received a request for a 8.312"-dia. hole saw saw to cut holes in 1/4"-thick, multiple-wall polycarbonate. Saws this size are not commercially available, according to Nuskey.

He made one out of 3/4"-thick aluminum and a 1 1/4" bandsaw blade. The blade is held on the aluminum with pan head screws set at a 5° angle to pinch the blade into the corner of the rabbit in the aluminum disc.

"In this day and ago of micrograin carbide, diamond tooling and 800-ipm feed rates, sometimes solutions are found in old-school methods," Nuskey stated. "Try not to forget the methods our fathers used."

The hole saw produced a hole in 6 seconds. The previous method with a sabre saw would take 6 minutes.

He can be reached at (215) 355-3391.