Cutting an F600 gauge panel

[sargentrs]

Modifying my F600 gauge panel to accomodate Autometer gauges and it's taking way too long. I've had a cheap HF electric tool for awhile now and the chuck stripped so it had a problem with the bits working their way out. So I caught a sale at Home Depot and bought a new Dremel 4000. Awesome tool! It came with a variety of bits and I also picked up a couple others that were suitable for metal cutting. Even with that it took me a solid hour to cut out one hole! I tried cut off wheels, cutting burrs, grinding burrs, etc. I finally used my aviation snips to nibble away the bulk of the metal and dressed it up with a grinding bit. There's gotta be a better way. Any recommendations? Any and all input is greatly appreciated!

[dailyf100]

I use a rotary file on a 90 deg die grinder. I good rotary file will cut through that like butter.

[sargentrs]

Thanks, dailyf100! Something like this? http://www.ebay.com/itm/SL-51-CONICAL-1 ... tuK_azU2hw

[eggman918]

I did mine with a hole saw,first I secured a piece of 3/4" plywood behind it with screws through the 4 holes that held the cluster to the panel that gave enough support to the assy. that it could cut through without any surprises..made it an easy job
The finished product

[sargentrs]

Thanks, eggman! Are those 2-1/16" gauges? I had my concerns they fit without bumping into each other. Only hole saw I could find was only for wood and I didn't think it would cut through the sheet metal even though it's so thin. Here's the plan...

[dailyf100]

Thanks, dailyf100! Something like this? http://www.ebay.com/itm/SL-51-CONICAL-1 ... tuK_azU2hw

Yes, but a larger barrel if you can find one. I have a couple that are 3/4 in diameter and a couple of 1 inch.

[sargentrs]

Yes, but a larger barrel if you can find one. I have a couple that are 3/4 in diameter and a couple of 1 inch.

Thanks for the tip!

[eggman918]

Thanks, eggman! Are those 2-1/16" gauges? I had my concerns they fit without bumping into each other. Only hole saw I could find was only for wood and I didn't think it would cut through the sheet metal even though it's so thin. Here's the plan...

Yes 2 1/16" the Home depot saws worked OK just run them slow

[sargentrs]

Thanks, eggman! Ok, I couldn't wait on a bit. Besides, family was getting on my nerves so I went down to the man cave. 30 little cut off wheels, 2 grinding bits and 3 sanding drums later, I got 'em cut out. Got it down to a system so it only took me about 20 minutes to cut one out. I'll get my rotary file and work on the holes on the left for the Autoloc button switches.