Check out Travers tool on the web. Look at piloted hole cutters. I used one with a 1 1/4 inch cutter to make some of my gage holes for my dash. They have some that are much cleaner than the big box store hole saws. I would post a picture if it was not so hard to do on this site.
Aircraft structure built.
Going at a snail's pace, life gets in the way.
Working on cowling.
My, how times have changed....
Back in the day.... when people actually had to build an RV (vs just put some parts together), This was the standard tool for cutting all of the lightening holes in wing and empennage ribs and many other parts.
Yea, that's right. All parts were solid with no openings (or pre-punched rivet holes).
I used to call these things the widowmaker...hahaha hated using those things
...but did on many occasions
HIGHLY RECOMMEND A FOOT SWITCH WHEN USING THE DRILL PRESS! Approx. $35.00 and may save your hand if or WHEN something grabs. Your foot becomes the third hand that can turn off the drill press if needed.
I guess this is all academic now since bkervaski already got his hole cut, but clearly the hole punches (we used to call them chassis punches) are the way to go. A lot of EAA chapters own a set. You can buy large ones for the instrument panel, too.