[Shop-talk] Drilling holes in sheet metal

[John Miller]

>    Drill an ugly 1/2 hole and expand it with a dremel?

Is it a flat or contoured surface?

I've got a few old radio chassis punches in varying condition that 
sometimes come in handy for such things.

Failing that, I think I'd ink/paint the 3/4in diameter on the surface, 
use a really sharp 5/8 or 11/16in holesaw depending on how much wobble 
it had, then clean it up with a 1/2in or so grinding stone in a Dremel 
or die grinder.

John.