Radar arch lights

[trogers]

I would like to install new LED lights in my radar arch. The imtra lights I selected are a 1/4 inch larger than the previous so the cut outs will need to be widened.

Any thoughts about how best to expand the diameter in the aluminium arch?

My first thought was a deburring bit on my drill. The Admiral standing by with a shop-vac.

I have almost got one expanded but the tedious nature suggests that my idea is probably not the wisest choice.

Suggestions?

 

[Toolsntoys]

What I like to do is to use a hole saw the size of the existing hole and create a plug out of wood that would fill the current hole then use a hole saw to cut out the new size. The wood plug will keep your new hole saw bit centered.

 

[Boatsb]

Nest holesaws.