Quote:
Originally Posted by Daox
I'd suggest a good hole saw instead of a drill.
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Definitely use a hole saw vs a spade bit. A spade bit is likely to grab the material and spin it wildly out of control, or twist the drill from your grasp. Major bad idea! Even if it were to work, it could possibly induce some stress cracks around the edges which could haunt you later.
If you don't need super high precision use a small bit to cut several smaller holes along the tracing of the 1" hole till you can punch the hole out with a hammer, then clean it up with a round file. You'll still get a good looking hole, and it won't cost much. Make sure to keep your bit cool with lube; I've found even old motor oil or vegetable oil works great for keeping a bit cool.