An alternative to putting tape on the instrument panel to protect from the jig saw is to put tape on the shoe of the jig saw. That is often faster and easier when cutting many holes. Generally, it takes quite a while to wear through, but check it after every cut for integrity and replace if it is starting to wear through.

In my opinion the best tool to buy before starting the effort of building an home built airplane is a small CNC. It is a real force multiplier. I have bougth my first one 25 years ago and it is still working.

I have got to a hybrid version of what you did. Use a oscillating multitool with a fine metal blade in a vice or metal break as the guide. That way I don't have to drill corner holes. Just ease in about half way down the cut and back out to both corners. The oscillating multitools are far more controllable too. Hot glue gun is a great way to hold on the guides until you get them in the vice or clamps. Super Glue will pop off guides fairly well too when done. If you are going to drill corners and cut down the line, think about using a backing block that is double stick taped to the back for support so the metal doesn't oil can. You are always cutting into support that way.

Use of that angle die grinder with a light touch and firm grip can save many many hours in building, but it does require skill development! Absolutely worth learning, and great to see a proper demonstration of it. A great tool for fiber glass as well😀. Keep'em coming Paul!

Access panels next! And circular ones too. Thanks!

I love these videos! Super informative!

Very informative. Thank you for taking the time to make this video.

Love the straight edge never thought of that

This a useful tip!, I have a metal blueprint flat file with a dent and need to make a square opening on the inside drawer to hammer out those dent creases.

Thank you !

Nice, I learned a lot. Thank you

Very good tips. Thank you

Interesting . I'm doing something similar. Thanks for your help

This might sound silly. But how did you get the placement of your first drill holes so acurate? Thanks.

Thanks for posting this, picked up some new (to me) ideas for electronics enclosures. If the panel is thicker, it can be too much for the dremel cutter, and I'm wary of breathing in aluminum dust. I've found a jeweller's saw to be very helpful for the initial rough cut, which can be scored with the dremel or have a line of holes drilled. Filing is always the tough part, thanks for the ideas here. Anyone tried this kind of thing with a mini-mill? I'm thinking it should work pretty well...

Great video. I have one suggestion…….Milwaukee!

Very cool. I like your sense of workmanship and safety. I just cut a bunch of square holes in a thick steel cabinet with my angle grinder. What a mess I made. Too thick for a Dremel. Maybe next time I’ll use a saber saw. How do I cut 4” diameter holes (for vents). Thanks, Paul

Thanks , I did it your way

Hi. I like your videos. You make everything look easy. I have an aluminum box (Bud Industries) that I’m using for an electrical control box. I need to drill some holes for things, but I also need to cut out some rectangles for a rpm display and a power plug. I have a Dremel, a drill and an angle grinder. What’s the best way to make nice rectangular openings in this box? Thanks, Paul

What the best way to get the lines as straight as possible? I have to cut slots onto the hood/bonnet of my car to get the car back to standard as for some reason it's got the wrong one on. And I can't just buy another as the car is extremely rare. I'm doing all the work to it myself so just trying to find great solutions. Great video by the way I enjoyed it :)

Regarding your step drills, is that something you would want to avoid the cheaper brands or in your experience they have proven to be fine?

Just wondering what your thoughts are on using a nibbler?

thank goodness for round hole digital gauges ;)

8:30 Grinding steel into aluminum 😬🤫...I like the idea of a guide though

Stupid of me to ask you how to cut rectangular holes when you just demonstrated the process. But my material is thicker and some of the openings are small. Think of one of those squashed rectangular power receptacles on computers and you get the idea. I think your technique of drilling four corner holes and using a Dremel is my best bet. Followed by a file of course. 😬 Thanks. Paul

What, no safety gloves!?!

Another cutting method is with a palm router.Constructing a basic jig guide is recommended Takes longer but the result is way better than a crude jigsaw which is tantamount to a whore's handbag of a job Do a job properly or don't bother doing it at all

Welp, I've learned something today. Great series!