DIY Chassis.

[pinkphiloyd]

...then use a hand tool to clean up the edges, not sure what it is called yellow handle with hooked swivel blade on end...

This is a deburring tool. Here's the one I have. It is the bee's knees. I don't know what I did without it. It's quick and very effective.
http://www.mscdirect.com/product/details/05751003
One of these is a must-have if you use a step bit.

Duly noted, thanks!

[Structo]

Do any of you guys make socket holes with a hole saw?

I see Harbor Freight has a 10 pc hole punch kit for $25.

Or use a step bit for 9 pin and 8 pin socket holes.

[Phil_S]

I tried a hole saw one time. I suggest several weeks of practice on scrap metal and you may be able to get by. Not recommended for tube sockets. Probably fine for making a hole in the floor for a gas pipe or for electric conduit.

[M Fowler]

I tried the hole saw too but I'd rather use a step bit when I didn't have the correct hole punch.

[JMFahey]

I've used hole saws on aluminum chassis with good results, NOT the cheap Chinese "10 flimsy saws fitting in a flimsy potmetal holder" but bimetal Starrett cup saws.
http://www.starrett.co.uk/shop/holesaws ... _hole_saw/

[img:250:278]http://www.starrett.co.uk/images/hole_s ... aw51mm.jpg[/img]

https://www.youtube.com/watch?v=Q3jVwoFRB

the main point is that they cut just where it's needed, while stepped drills have to go through all the smaller ones first.