I'm not sure how, using the tools I have, to carve
big holes in a
thick aluminum blank panel plate. Would a 3 HP router and a carbide
bit do it?
Get an engraving bit - that is more or less what they are designed
for. If you get one perhaps 1/8 inch diameter, you would only need to
file out the corners a little bit. With an 1/8 inch thick panel, you
might need to make the cut five or six times, but it will go fast.
--
Will