Emmett wrote:
"cutting the RO for the new bucks can be easily done with a combination of a Dremel plunge bit for the OSB or other panel enclosures and any convenient recip to remove residual foam."

Aha--this is another option. My little Dremel is a pretty weak tool--is there some industrial-strength one? Perhaps a long plunge bit on my router would work as well? As for the foam, I figure with the new panel work, plus all the new window openings, I'll splurge for the custom grinder that Winter Panel sells, and then resell when I'm all done (a couple years from now...)

So, has anyone used a long router bit for cutting openings in panels? Or is the width of kerf too big and the flying mess too awful?

thanks, Richard