Pictures of some of my Modded PS1 consoles

Instead of dremmel, have you considered a hole saw? Drill a pilot hole in the exact middle, find a hole saw that is about the right diameter and drill the whole piece out. Neat round hole every time. You should be able to find one around 4.5" diameter and matching shank at most hardware store. You do need regular drill since shank is usually 1/4" and dremmel doesn't handle anything that big.

 

I was thinking the same thing but I forgot the name of the tool. There is a floor mounted Tool that you used to drill holes (I guess its a Drill but a floor mounted one not a cordless one), and you can change the heads to a circular shape. My concern would be if the circular bit isn't sharp enough it might crack the plastic. But it would be easier and take like 10 seconds to do.

 

Sounds like a drill press?

 

Thats it! It was bugging me that I forgot the name of my own damn tools

 

You do some great work op! Keep it up.

 

Nice tutorial, thanks for sharing. I need to get me a dremel and maybe have a go on some busted up consoles.

 

I'm currently making a video tutorial on how to properly make a perspex window in a ps1, I'll post it on here once it's finished.