For the technical update... I have been making many square holes successfully. I have been boring a round hole first then going through by hand with a 1" chisel from a hollow chisel mortiser. It really does work quite well. The main difficulty is the chisel getting jammed in the hole, although the chip ejection slot on the chisel makes an excellent place to use a small pry bar and fulcrum to pop it right out. Thanks again for all the input, it certainly helped.
