CattleRustler

yeah, files are a must. If you can only get one to start, I suggest a double-cut half round file. The rounded edge is perfect for fan holes, and it will have a flat side as well for deburring flat/straight cuts. I am getting started on cleaning out and reorganizing my workshop today, as soon as my gumdrop build comes upstairs and is presented

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Syrillian

I wish I could be there to see the look on her face... it'll be priceless.

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turkey4550

A hole saw is the best, i have found tha cutting in reverse gives you a very controlled cut. As far as a drill, corded drills have more amperage thus more torque. That is not necessarily always a good thing. If you are making several cuts close together, say for rad fan holes, a overly powerful drill, if it gets hung in the cut, could deform the cutting surface, not to mention cause bodily harm. I have a Snap-On 12volt drill it works flawlessly.

On the other hand. The hole saw attatchment pictured earlier, partnered with a router (sideways)bit can also do a quick and clean job.

One more and possibly the most important when cutting on your case. Protect the finish surrounding the job. Cover the entire surface you wish to augment with masking tape. Then draw out your cuts directly onto the tape and cut through it. If you slip making a cut you are far less likely to damage the surrounding areas.

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