Hole saw set

[Warzin]

Hello, I am planning to do my first proper wood project and I was hoping to get some help. I will be making a pair of wood cups for a pair of Grado headphones and will need to cut 4 holes per cup so I thought I would just get one of the hole saw sets I see on ebay/amazon and just use my drill. Now i did a bit of searching/reading on the forum and realise that those sets might not be too good and will most likely be disposable after my project is done. Can anybody recommend me a set (or individual) of hole saws? I need 44mm, 50mm, 64mm, 76mm sizes. I dont want to pay too much but also dont want to waste money on something that will not work, maybe £10-20 if possible? I dont have access to any tools but my drill unfortunately.
Anyway, hope some one can help me out. Thanks
David

EDIT: actually the most important hole is the 50mm hole where the driver will be places inside....after that the other hole measurements are quite flexible....as long as there are 2 bigger hole saws over 52mm....and 1 hole under 50mm
OH and i already have a arbor...maybe i should just buy them individually?

There is a nice Irwin set on ebay for £30 but i wont be using most of them (22,29,35,44,51,64mm)...and i will probably still need another >50mm hole saw

 

[Phil Pascoe]

No tools but a drill? Have you a vice? You'll have a hell of a job with the larger holes if you haven't.

 

[AndyT]

The lowest cost option is to buy a coping saw. Drill a ring of small holes, join them up with the coping saw, then make good with some sandpaper wrapped around a stick.

But that might not give a precision made look...

Maybe a more practical approach would be to buy single holesaws a step up in quality, use them, then sell them on afterwards.

You may find it difficult to control a large holesaw without a drill stand or drill press.

And as Phil says, proper workholding is essential.

One other thought - I don't know what these headphone cups are but if you want to use holesaws you will need to drill all the way through. If you want to make a deep, stepped hole into thick wood you need Forstner or sawtooth bits.

 

[Warzin]

Sorry, yes I do have a vice and stuff like that, I just meant I do not have a lathe or drill press. I have never heard of a drill stand, that might be something to look into if its not too expensive. The headphone cups are just 2 wooden rings glued together so a 76mm circle with a <50mm hole and another 64mm with 51mm hole for example
I attached a picture for a similar pair some one else made.

 

[Warzin]

This is a pair of oak ones that i made around a year ago with 2 hole saws that my dad gave me but i think they were quite blunt because it took a very long time to drill through felt like i was burning through rather than cutting through so i figure his hole saws might be quite old.

 

[bugbear]

This may be informative;

http://headfonics.com/2011/07/grado-diy ... ect-woody/

(I think tonewoods only have tone when used in thin, resonant x-sections for acoustic instruments, but maybe that's just me)

BugBear