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Permalink Reply by Jim Morris on October 12, 2016 at 3:01am

Here's something I've seen HVAC folks use and is on my list of tools to get.

http://www.ebay.com/itm/SHEET-METAL-CIRCLE-HOLE-CUTTER-DRILL-ADJUST...

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Permalink Reply by Fomhorach on October 12, 2016 at 10:11am

It's what I did. Marked an X to each corner, cut the x with a dremel, then bent the metal inwards. It gives little flaps to attach to the wood.

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Permalink Reply by darryl kernaghan on October 12, 2016 at 12:46pm

The dremel is ok for an initial cut, but if the surface has a nice paint/print finish, and you want a non round shape, simplest way is make a hole, then just use jewellers snips to shape it, it's very easy to overcut with a dremel cutting disc

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Permalink Reply by Ron "Oily" Sprague on October 13, 2016 at 2:17am

12-gauge steel shot will make it look like a nice old resonator...

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Permalink Reply by Ron Burgess on October 13, 2016 at 11:46am

 I have used sharpened hole punches with scrap wood underneath.

Works fine.

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Permalink Reply by Ronald Hanes on October 25, 2016 at 6:22am

Thanks for all the help.  I ended up using a hole saw in my battery powered hand drill.

Took it slow...worked fine. Didn't cut my finger until after it was done. I was checking to see how smooth it was..smooth and SHARP now I have to split some tubing and cover the edge of the hole.

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