In article , "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?

Drill a 3/4" hole.