A sheet metal hole cutter (10) has a cap plate (12) defining a substantially circular peripheral groove (14) and an annular shelf (16) extending radially outwardly from the peripheral groove. An elongated band (18) forming an approximately circular shape with opposite ends of the band contacting each other defines a base edge (22) received within the circular peripheral groove in an abutting relationship with an inner edge (24) of the groove. The band defines an axial depth (D2) of about 1/2 of an inch or less, and an outer diameter (F) within the range of about 9/16 of an inch through about 6 inches. A weld region (26) fixedly secures the base edge of the band to the cap plate. The annular shelf of the cap plate extends radially outwardly from the base edge of the band and defines a radial depth (D1) of at least approximately 1/16 of an inch in order to prevent over-feeding of the hole cutter through a work piece. A plurality of teeth (30) are disposed along a cutting edge (28) of the band, and each tooth defines a cutting surface (44) extending between an outer edge (40) and an inner edge (42) of the tooth. Each cutting surface is oriented at an acute angle (A) relative to the plane of the cap plate such that the outer edge of the respective tooth is spaced further away from the cap plate than the inner edge to thereby preferentially cut the work piece with the outer edge and create a substantially burr-free hole in the work piece.
