In this video tutorial I demonstrate how to fit a new LED downlight and how to enlarge and existing hole saw hole in the ceiling if you are replacing an LED downlight for a larger diameter downlight. Hole saws rely on a pilot bit to guide them, it’s tough to enlarge an existing hole because there’s no material for the pilot bit to bite and remain centralised. I get around the problem of having no guide for the central pin of the hole saw by developing an ingenious jig to create a temporary guide for the hole saw central pin and attach it to the ceiling while drilling the new hole and then removing it after the new hole is perfectly enlarged. After some filling, sanding and painting of the plasterboard the final result of the downlight neatly installed demonstrates how successful this technique is in producing a very clean finish.
Step 1. Remove old LED downlight and make a centralising jig.
Step 2. Secure jig in ceiling
Step 3. Re-drill hole with larger hole saw, using jig to keep hole saw centralised.
Step 4. Fill and paint holes from jig fixing screws.
Step 5. Install new light by plugging it into the electrical socket in the roof, passing the cable through the hole and inserting downlight by activating the springs being careful not to trap the cable.
Job successfully and neatly completed.
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There are some other techniques to enlarge a hole saw hole for instance if you happen to have both the old and the new hole saw sizes you could mount them together on the drill bit or arbor and the old (smaller size) will act as the centralising guide.
This video is a good demonstration of this: https://www.youtube.com/watch?v=NECLySkPvdU
Alternatively one could make a thick wooden cutout with smaller saw and mount on the drill bit as guide for the larger hole saw as demonstrated here: https://www.youtube.com/watch?v=vOUfFaIJUqo
Here is another good DIY idea:
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