"Gunner" wrote in message
...
snip----

there has to be a better way.

There is, and you won't believe how simple it is.

I think it's Stanley that makes an adjustable circle cutter. It's a fly
cutter of sorts in that it uses a 1/4" HSS lathe toolbit that is held in an
arm with a set screw. The body has a 1/4" drill that acts as a center, so
all you have to do is set the arm out to spin the circle you desire and cut
away.

Before you jump to conclusions and suggest to me that it won't work, be
advised that I cut all the openings in the 400 amp switch and the CT can for
my 3 phase service with one, using a half inch Milwaukee drill. I cut
several holes.

Yep! Did them by hand, and it works great. Requires a little skill, but I
know you could handle it easily.

Remember, the items I cut are made of steel. Cutting aluminum would be a
breeze. It does require some skill in grinding the tool, and constant
lubrication, but you can handle that with something as simple as an acid
brush.

Harold