What would be the easiest way to increase the diameter of a hole from, for example, 58mm to 63mm? I have a number of spotlights that I want to replace, which require slightly larger holes. They are aligned in a row, so I want them to stay in line.
Buy two hole saws and a suitable traditional holder.
Mount the 63mm saw as usual in the hole saw holder.
And in the 63mm saw, you can then thread in a 58mm hole saw as a guide. There are usually several threads left after mounting the first saw (image 2). I have done this several times when you need a "guide" to center the large hole in the middle.
Another solution is to drill a 63mm hole in, for example, a plywood or MDF and place this over the hole to use as a guide. It's important to hold it and proceed cautiously.
And depending on how it looks (ability to access the top and distance between the spots, etc.), you can also consider adding a strip of particle board, a facing board, or something else over the row of spot holes. Then mark the center of each hole (align the line now if it misses a few mm somewhere) and make new holes with a 63mm hole saw, where the board/plank acts as new material to center the hole saw in.
I couldn't fit two hole saws in the holder, so I sawed out an equally sized hole in the plywood and hot glued it into the existing hole, then it worked fine.
As previously written, it is convenient to place two hole saws in the same holder where one guides and one creates the larger hole. Both Profit and Starret have a holder made for this...
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