I'm looking at custom building a few control panels that will require several large meters in a small area of a factory built box so I will be drilling/cutting several large holes in close proximity to one another. Hole saws and KO dies tend to buckle the metal and the end visual product is very important. I have consider sending them out but will likely be $$$. With all the cool tools in the trade, any thoughts out there on on something that can cut a 3"+ holes in 14 gauge steel without being so abusive to the surounding area and leaves a clean finish. There will be an inch or so between the big holes. The plate will be swiss cheese by the time I'm done with it and it need to keep its shape.
My best guess is clamp the cover to plywood, layout the pattern, use alot a fenice and hole saw the large holes first and work my way down. I need to find someone with a milling machine.
Any thoughts?
