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G/day Mark hows things?...... Im a metal finishing technician by trade & one of the tricks I know of with hole saws & jigsaws is velvet soap the cheapest one you can buy it works a treat specially on thin metal & aluminum. It also works great when cutting, grinding or sanding alloy with ether a grinders or disc sanders. It stops the material burning.
Hope this helps
The only trick I can suggest is take it to ARB or similar to fit. They do dozens a day and should know what they're doing.
Maybe I just don't trust myself drilling a 90mm hole in a panel..haha
Jeez that guys a bit of a hack with the cordless...haha
Yeah thats why Andy posted it "To Show Why you don"t use that method" But in saying that I don't think the cordless was the problem. It was more the goose on the end of it....lol
Yeah It's a bit of worry slippling and putting some scratches on.
I'll make sure I'm sober before attempting the cut...haha
I've been known to modify things late on Saturday night and making huge mistakes.
I don't think you will have a problem Mate as you know your way around metal pretty well anyway & you don't sound like a Bloke who lacks common sense...The fact your on here asking questions BEFORE you commence the job is proof enough of that so happy modding & don't forget the progress pics & a full report on how you did the mod so I don't make any mistakes with mine....lol