A local kid asked me to make him a pickguard for a guitar. He had his old one to use as a template, and he wants it made from diamondplate aluminum. I have been working on this, and I got the stuff cut OK. Inside radiused corners in enclosed holes were difficult, but I finally did OK using a jeweler's saw in a scroll saw. I have to drill a bunch of 7/64" holes, one 1/2" hole, one 7/16" hole, and
3 3/8" holes, all working from punch marks. The stuff doesn't drill very well using normally ground twist drills. I haven't tried punching it, but figure it might be difficult because of the diamond texture. What is the best way to make these holes?Grant