Ever thought about a nibbling tool? Not one of them manual things, but the one that either fits into a drill or the proper thing that is run by electricity or air?
I remember seeing a thing on TV here last year during one of the many Info-mercials I wake to in the morning, that gave a clean (not sharp) edge. I'm not suggesting you buy one of THEM, but ask at your local Trade counter and see what they can do, if a guy on an Infomercial can use a nibbler, crikey, you're home and hosed!
I have an air nibbler and when I do it you think there was a bionic rat loose in there. The hole definitely looks chewed.
I'm sure there is a guy on TV who can cut perfect holes with one but I also see carny barkers who can throw that ring on the beer bottle every time from a meter away.
I have couple diffrent verison of nibbers one is air and the other one is electrique verison.
Both do good job but just don't push them hard otherwise you will get jazzed edges which you will have to (BEEP)around with it later.
And make sure you have right nibbers due some are only work on thinner gauge and some will work just fine on thicker gauge so that the other item you have to look out for it.
Holesaw yeah .,,, I make myself a jig to hold the holesaw in place so it will not skew out of the place. { I made that from a peice of steel and milled out with CNC machine which I barter with one guy.
Die grinder it will work but just don't dwell at one spot too long otherwise you will have a major opps to deal with it.
Merci. Marc
Pas de problme,il marche n'est-ce pas?"(No problem, it works doesn't it?)