In a message dated 1/22/05 11:32:20 PM, rrecardo@WEBTV.NET writes:

<< Break out the cutting torch.

Pop,
Ssssshhhhhhhhhh,
Done.

Might be a good idea to take a look at what's under the Van prior to
lighting up.

RC >>

Roberto, I'm surprised at you!  Do you really think it is a good idea to tell
someone who is asking how to pop a hole into some sheet metal, to strike a
torch?  Maybe we should call this "How Do You Spell KA-BOOM?".

A hole saw will work well as long as it is not made from Chinese scrap metal
and you can hold the speed to less than 100 RPM.  A sabre saw with a 32 TPI
blade will work if its blade width can swing the radius you're trying to cut.
Hole punches work great, I've used them on material up to gauge 12, but they
cost what they are worth.  The die grinder/burr hookup will get you there at a
slow rate, but those tiny pointed cuttings from a burr don't exactly brush off
your skin.  Crudest but effective method - drill a series of holes spaced as
closely as possible around the circle, snip the metal between the holes then
smooth it with a file.

Mixed blessings anecdote:
A buddy of mine has an industrial nibbler which easily eats though anything
up to gauge 10, just pull the trigger and point it where you want to go.
Whenever the nibbler first came into his possession, everyone he knew wanted to use
it . . . one time.  It seems in doing its thing, this wonderful tool creates
thousands of crescent-shaped cutting with needle sharp points which imbed
themselves into anything within a fifty mile radius.

George