How to Drill Clean Holes in Plywood Without Splintering

When building DIY camper van cabinets and furniture, plywood is an excellent material because it's strong, lightweight, and durable. But drilling through finished plywood can leave an ugly problem: splintering and blowout on the back side of the hole.

A normal twist or HSS drill bit can push through the thin outer veneer before completely cutting the wood fibers. Fortunately, there's an easy way to get a much cleaner hole.

For this method, you'll need a small twist/HSS drill bit and a brad-point drill bit in the finished size of your hole.

Step 1: Drill a Tiny Pilot Hole

Start with a very small twist or HSS drill bit.

Mark the center of your hole and drill completely through the plywood. This small pilot hole establishes the center and gives you an accurate reference point on both sides of the plywood.

Step 2: Score the Top Veneer

Switch to your finished-size brad-point drill bit.

Place the center point into your pilot hole and drill only about 1/16 inch deep.

A brad-point bit has cutting spurs, sometimes called ears or wings, around its outside edges. These score the wood fibers around the circumference of the hole before the rest of the bit removes the material.

Don't drill through yet. You only want to cut through the outer veneer.

Step 3: Flip the Plywood Over

Flip the plywood over.

Because the pilot hole goes completely through the plywood, you now have the exact center of your finished hole on the back side.

This allows us to cut the back veneer before the drill bit breaks through it, which is the key to preventing blowout.

Step 4: Score the Back Veneer

Place the same brad-point drill bit into the pilot hole from the back side.

Again, drill only about 1/16 inch deep—just enough for the outside cutting spurs to score through the veneer.

Now the wood fibers surrounding your finished hole have been cleanly cut on both sides of the plywood.

Step 5: Drill Completely Through

Now drill completely through the plywood using the brad-point bit.

Use a good drill speed, slow feed, and light pressure. Let the drill bit cut the material instead of forcing it through.

Pushing too hard can cause the bit to grab the plywood and tear the veneer.

High speed + slow feed + light pressure = a cleaner hole.

Why This Works

When a normal drill bit exits plywood, it can push the final veneer outward before cutting through it. That's what creates the familiar splintered blowout around the back of the hole.

By scoring both surfaces first with a brad-point bit, the wood fibers around the hole are already cut before the drill passes through them.

The result is a cleaner, more professional-looking hole on both sides.

A Simple Trick for Better DIY Camper Van Builds

Small techniques like this can make a big difference when you're building camper van cabinets, beds, shelving, and other plywood van furniture.

Always use sharp drill bits, and if you're working on an important finished panel, practice on a scrap piece of the same plywood first.

At TNTvans, we're big believers that you don't need to be a professional van builder to create a professional-looking camper van interior. Having the right materials, tools, and techniques makes DIY camper van projects much easier.

Quick Recap

1. Drill a tiny pilot hole completely through the plywood.
2. Score the top veneer about 1/16" deep with a brad-point bit.
3. Flip the plywood over.
4. Score the back veneer about 1/16" deep.
5. Drill completely through using light pressure and a slow feed.