Stop a Non-Quick-Release Hole Saw From Fusing to Its Arbor With a Copper Washer

The Problem

Some hole saws mount to their arbor with a plain metal-to-metal fit rather than a quick-release mechanism. Cutting generates heat, and repeated metal-on-metal contact under that heat can gall the two surfaces together, leaving the hole saw stuck fast on the arbor after the cut.

The Technique

1. Before mounting the hole saw, find a piece of soft copper wire or copper cable.
2. Flatten a section of it into a small washer shape that fits at the base where the hole saw sits against the arbor.
3. Place it between the hole saw and the arbor before assembling as usual.
4. Cut normally. The copper squashes down under the assembly pressure and holds up for repeated use, so it doesn't need replacing every time.

Copper works because it's soft enough to compress and separate the two hard metal surfaces, preventing the direct contact that causes galling — and unlike some washer materials, it holds up to years of reuse instead of wearing out after one or two cuts.