To make holes, you need two things:
- A drill press - you'll never make accurate holes without one. Clamp everything down!
- A "stepped bit" hole enlarger - it's hard to do a great job by drilling successive holes and changing bits each time.
More on drilling holes here:
http://www.geocities.com/budb3/arts/meth/drill.html
The most professional results come from using a laser cutter and building a completely new faceplate from scratch. I'm lucky enough to have a TechShop just up the road where I can use one for $30 a day.
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