The image below depicts a bevel cut side view. The smaller the angle the more the piece will extrude. The amount of relief depends on the thickness of the wood, size of the blade and the angle. In this project I used 1/2" thick wood, a #3 blade and a 1.8 degree angle. Your results will vary so make test cuts.
When you drill the interior holes it's best to use the smallest drill bit you have. I used a #57 micro drill bit and a #3 blade combination. This small hole is much easier to hide. It's also best to drill the entry hole at the same angle as the bevel.
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Information: Micro Drill bits.
There are times when it is important to drill a very tiny entry hole. The project above is a good example. To hide the hole as much as possible I used a #57 micro drill bit. That is slightly over 1 mm. I chose this bit because I knew I could still get a #3 blade through the hole. The #57 is also large enough that it does not break as easily as the smaller micro bits. I have found that a #55, #56 and #57 will do most of what I need.
Another example where a very small drill bit is an advantage is interior veining of a pattern. If the vein does not start on the edge of a pattern you will have to drill a starter hole. Hiding a small hole is easier than hiding a large hole.
The last example is very small fret work. There are some patterns where the interior cut is too small for a standard size bit. Micro bits to the rescue.
These bits are too small to fit in a standard size chuck. You need an adapter chuck like the one I have above. Here is the Amazon link for this chuck. This chuck will fit in to your drill press chuck.
You can purchase the micro drill bits at this Amazon Link or you can buy them in small packs at this site. For scroll saw work I would not buy much smaller than a #55. Remember that a #71 bit is smaller than a #47. The numbering system is backwards from the actual size of the bit.
Using anything smaller than a #57 bit in a powered hand drill is very difficult. The bit will nearly always break. Even the larger micro bits will often break in a hand drill. You need a drill press or a pin vise. The pin vise is a hand held drill. They are effective on thinner wood but still difficult on anything thicker that 1/4". Here is a link to a pin vise.
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