Need to cut disk of wood to plug hole

[slicendice]

I am trying to attach the hinges to a cupboard door for an integrated washing machine. The door was originally fitted to another washing machine and (of course!) the holes for the hinges need to be in a different place for the new machine.

Unfortunately the location where the new holes need to be just overlaps the existing holes, so I need to plug the old holes with a disk of wood so I then I drill new holes in the correct location.

The holes for the hinges are 35mm wide and 12mm deep, so I bought some holesaw drill bits from SF that included a 35mm bit, my thinking being I can cut a 35mm disk of wood which I can then use to plug the old hole. However, the measurement for the drill bit is from the outside edge, not the inside edge (i.e. it cuts a 35mm hole, but the disk of wood produced is only 33mm wide). So I now have a 33mm disk of wood that rattles round in the 35mm hole I'm trying to plug.

Can anyone suggest how I can produce an disk of wood that is exactly 35mm wide which I can then use to plug the hole?

Sorry, that all got a bit wordy! Hope the attached pic makes it a bit clearer what I'm trying to do - the (badly drawn!) red circle is where the new hole needs to be, which as you can see overlaps the existing holes.

 

[Tigercubrider]

Holesaw Kit

Use these holesaw blades from Toolpak to drill neat holes into plastics or wood. Tough thermoplastics such as polyvinyl chloride (PVC) or acrylonitrile butadiene styrene (ABS) will give way to the fine threaded blades to create a smooth-edged hole. The holesaw kit gives you a range of seven...

www.toolstation.com

This is an example, it is designed to cut a hole to allow pipes etc through cabinets.
You will end up with a disc of wood inside the circular sawlike part.
The disc will also have a central hole for the pilot hole.

You need to find a piece of wood the depth (or close) to the depth of hole to be filled, or close.
If the disc is too large, sand the edges.
You can try to use it with the centre drill being set back so it doesn’t actually cut into the wood that you want.
Mix sawdust with the glue.

 

[Munroast]

do a search for
Adjustable Circle Hole Saw Cutters
with a bit of time a patience you will get the right size
if you have a really rigid pillar drill you may get away without the centre pilot hole

 

[slicendice]

Thanks Tigercubrider

I have one of those kits already but I'm having trouble getting the drill bit to stay mounted when using it though. I tighten the chuck up as tight as I can get it but as soon as I start drilling into wood, it just comes loose.

I've just checked and it looks like the pilot hole drill bit used to attach the saw attachments to isn't quite straight...so when it's spinning, the tip is moving slightly from side to side.

 

[Alec_t]

For aesthetic reasons a perfect-fit disk is appropriate, but if aesthetics aren't a concern then your approximate-fit disk would be fine when glued in.

 

[Stuart981]

Just fit the disc you have cut with JB Weld.

 

[Tigercubrider]

Are you sure that the drill bit provided is straight? And is in the centre of the chuck?
Don’t push too hard, let the teeth do the work, you just need to keep it level.

 

[stevie888]

Drill a bit of scrap wood with your hole saw as normal then clamp it to your workpiece and use the hole saw without the pilot drill. The wood keeps the saw in place.

This dodge also works if you need to enlarge holes: eg to fit bigger downlighters.