Re: How do you cheesehole?
 

why do even want to make cheese holes?

if it's a weight problem you could try something more effective like writing less code in your programing you know those bit and bytes of code weigh alot.

Re: How do you cheesehole?
 

For quick clean nice looking holes in thin material nothing beats a Hougen Rotabroach Cutter. An 11075 set should be in every teams tool box. An 11075 set isn't too expensive (<$80) and works great even in a hand drill.

http://www.hougen.com/cutters/kits/cutter_kits.html

http://www.ohiopowertool.com/rotabroach.cfm

Re: How do you cheesehole?
 

that would be way overkill for 1/8 inch aluminum. I have never done it before but it would be easier with a hole saw or step drill.

Re: How do you cheesehole?
 

Aluminum cannot be cut with an oxyacetylene torch, even though I have tried, unsuccessfully.

Re: How do you cheesehole?
 

...With a CNC Turret-Punch machine. :D

Watching one of them go 'ch-plunk, ch-plunk, ch-plunk' as it not only cuts out all your parts but cheeseholes them at the same time has the same joy as one experiences after using a calculator for the first time in their life, after solely doing long division by hand.