Metal Magic: Making Square Instrument Holes In Aluminum


You’ve built most of your airplane, now it’s time for cutting the instrument panel blank. KITPLANES editor at large Paul Dye shows you how to make a square hole in aluminum sheet, a skill you’ll need with today’s modern “glass panels.”

This series is sponsored by Aircraft Spruce & Specialty.

View the complete list of published Metal Magic videos.


  1. using the dremel with the plane of the wheel facing the operator is dangerous should the wheel shatter as they are known to do and particularly with cheaper wheels.
    Better to have the wheel at right angles ie cutting from side to side in relation to the operator.
    (old habit from a butchers shop – never cut towards the body !)

  2. These videos are always helpful.
    I appreciate that you recognized the limitations of a vise, and introduced the steel strip and clamps!


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