What is the best tool to use for making a 2 inch hole in a piece of thin sheet metal?

In this scenario, the most appropriate tool for making a 2-inch hole in thin sheet metal is a hole saw. A hole saw is specifically designed for cutting circular holes with precision in materials such as wood, plastic, and metal. It consists of a cylindrical saw blade that creates a clean cut and produces little waste material. This makes it highly efficient for larger holes, such as the 2-inch size mentioned.

Using a metal punch is generally better suited for creating smaller holes, usually less than an inch, in thin sheet metal. It functions by using a mechanical or manual force to create a hole by shearing the material, which may not provide the desired clean edge for larger cuts.

A circular saw, while effective for cutting through various materials, is not suited for making precise circular holes. This tool is typically used for straight cuts in larger materials and can be more challenging when trying to achieve a clean circular hole in sheet metal.

A drill bit could make circular holes, but the standard drill bit may not effectively create a hole of that size in metal without risking damage or not achieving the desired clean edge. Specialized bits, such as step bits, could work, but they may lack the efficiency and cleanliness of a hole saw for this specific application