What's Your Method?

[Tequila]

I'd use a hole saw - OD first then ID. And I'd screw the middle discard to a backer block to keep the piece from spinning on the second cut.

[Crash2510]

I like to do this in one motion so in the past i have taken a hole saw and put it inside another hole saw to cut both at the same time.

don't know how many you have to cut but i have had to use this before to make a hole bigger and it works pretty well.

[Bill in Buena Park]

Not sure I saw this method posted yet, so another alternative:

1. Hole saw disks from stock, oversize OD (2.75-3in);
2. On large disk sander, using circle-sizing jig with centering pin (smaller version of this - http://www.woodmagazine.com/woodwork...erfect-circle/ ), place disk on pin using pilot hole from hole saw, and sand disks to OD of 2.5in - or this might work too: http://www.woodmagazine.com/woodwork...er-circle-jig/
3. Prepare a sacrificial board with a 2.5in circular inset via Forstner bit on Drill press and two small toggle clamps placed to sides of inset (to hold down the disks), then clamp to DP table, insert and toggle clamp a disk, and cut center ID with 2in Forstner bit

[backpacker85]

Being basically lazy & not liking all the bit changes , I think I'd try the nested hole saws and try to make both cuts at the same time.

If I were starting from scratch (not limited to flat stock) I'd find some 2.5" round stock, bore a 2" hole into it, and start slicing off washers.

[Wood_workur]

hole saw, big then little. I have enough hold down and clamps to make it work safely.

[shoottx]

Count me in for using a jig on the router for the outside and a hole saw for the inside.