Scott,I'd buy a 3" hole saw with fine teeth for cutting metal for the corners. You won't get the holes any more perfect than that. Just make sure your pilot holes are measured exactly on center. Even if you don't push the hole saw all the way through it will give you a perfect score on the aluminum. I'd buy a long drill bit to do the pilot holes so it goes all the way through the pine on the inside. Just make sure your drill is plumb when you drill the pilot holes. Then just connect the dots -Sean [url=http://www.herdofturtles.org]www.herdofturtles.org[/url]1984 Eagle Model 10S
That's exactly what I'm going to do...3" hole saw is equal to a 1.5" radius right? So technically if I have 3" radius corners, I'd need a 6 inch hole saw?!