Butt Joint Question

[JoshStratton]

If you do it with a jigsaw or equivalent, drill a bunch of holes tangent to your cut line, and then saw inbetween each hole. Lots faster that way.

Oooooo great idea!

I wasnt sure how I was going to manage to get it cut out. I have a jig saw, but I was just going to get some more cut-off wheels for my Dremmel.

Ok, so here is ANOTHER question

When I cut the hole out, I know it wont be very smooth. Most of my cuts are kind of rough. How do you smooth something like that out when it is in the middle of a piece and keep it looking like it was punched out all nice and purty-like?

Here is an example of what I mean, sorta.





Those edges inside need cleaned up and they are hard to do. I may get a tail panel from a 69 like Travis (i think) suggested and weld the holes in, but just in case, I would like to figure out how to smooth these down.