I drill slightly-overlapping holes near but not actually touching the 
window outline.  Always back up the material with a wood block when 
doing this.  Then I remove the jagged center chunk with pliers, using a 
slight twisting motion.  Finally, I use jeweler's files to finish the 
opening.

Depending on the size of the opening and the amount of jagged material 
that needs to be removed after the center portion is gone, a Dremel tool 
with a cut-off disk or a milling bit can be used to remove material 
quickly.  If you do this, stop short of trimming to the outline, then 
change over to jeweler's files to finish-trim the opening.

Dick Karnes


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