burnoutstang":2loo5o89 said:What kind of saw/saw blade/hole cutter/tool thingy works to make that big of a hole? I have a dremel so grinding isn't a problem. Same deal with the belt sander.
You can use a hole saw that you can get at any DIY type store. They are primarily for wood but if you get a set that says it is "bimetal" it will cut through the cast iron easily enough. Just go slow using lower RPMs and let the tool do the work. Attempting to force it thru will just get the thing super hot & ruin the teeth on the cutter. Cast iron makes a lot of fine chips similar to dust so you'll have to keep the shop vac working at the same time.
Use a Dremel or other die grinder with either a carbide burr type bit or a med grit grinding stone to smooth the edges. Just use a sharpie and draw your outline then stay inside the lines. Think of it is the adult version of a coloring book

Good luck!