How big a hole? If you talking about 1" inch or smaller, then a chassis-punch is probably the way to go. 3/4" is about the smallest you can wrap easily with c-channel. Larger that 1" you could still use a chassis-punch, but they start to become expensive. (You also can join multiple holes with a nibbler to make slots) Hole Saws are competitive up to about 6", particularly in aluminum and plastic. After that, power tools like this are probably your best bet.




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