On Sun, 2 Nov 2008 17:04:16 -0800, "Walter R."
wrote:

I need to make (drill?) several 3/4" holes in 1/4" thick aluminum panels.

I have a 3/8" drill, a 1/2" drill bit, a 4" angle grinder, and hand files.
It's a tedious job to drill a 1/2" hole and then use a file to enlarge it to
3/4".

Any easy way to do this without getting blisters?

Thanks

'Try a tapered reamer

http://www.icscuttingtools.com/catalog/page_200.pdf