I've had a hell of a time cutting an opening in a sheet aluminum
instrument panel to fit new gauges.
Round holes are no problem -- a hole saw does it in a jiffy.
But retangular holes really screw me up -- a jig saw, no matter what kind of blade I use, violently vibrates the sheet without doing much cutting.
A Dremel tool with a cutting wheel
just disintegrates the wheel
I know I could clamp the sheet to a piece of plywood
and cut it together with the ply, but then I would have to take a bunch of instruments out first -- PITA.
Is there some kind of nibbler or some other better suited tool for this job?
Thanks in advance for any hints.