How big would these holes need to be? Torches are not the was to go as the
sheet metal will warp.
For smallish holes ( ~ 1" and under ) a Unibit works just fine. For larger
sizes, a hole saw works but they tend to cut over sized by about 1/8", leave
a ragged edge and are sometimes difficult to keep the hole where you want it.
For the radiused edges, use a lathe to make a hard wood die ( a hole with a
radiused edge )to support the back side of the steel. The next step would be
to make plug ( round with a matching radiused step), a ball on a stick, a
ball from a bearing, billiard ball or some other round object.
Depending on the size of the hole, thickness of the material and location of
the hole, use a drill press, vise, clamp, hammer or other device to form the
metal.
The size of the hole and size of the plug would need to be juggled a bit so
test on a similar gauge scrap piece.
Harold
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