Most excellent, sir! Very clever and a fine result. Thank you for a very good writeup and great photographic essay!

I'm always too poor to afford the cool tools so it's a challenge at times. On the metal shaping & reaming out ignition key hole [or whatever else]: any hardware store will have some little metal burrs for wood shaping, in various shapes & sizes. Last I looked they were between $3 & $6, pretty cheap. These have a 1/4" shank & will chuck right up into a cordless, electric drill or drill press. The conical one is pretty darned good for enlarging drilled holes like your ignition switch hole & several other tasks. Others are barrel shaped or round. Talking about the ones with actual teeth all round the circumference, not the one with more of a series of cutter blades. I've found even the cheaper ones hold up very well for metal shaping, aluminum or mild steel. I've had some last for several years of occasional use in metals. As they wear, retire them to finish work instead of hogging out. In aluminum it's good to clean the teeth on the burr with a wire brush, powered or otherwise.

Also the hardware stores have cheap hacksaw blades to fit almost any jig saw or reciprocating saw. There I prefer to search out Lennox brand blades but the others work okay too. Metal specific hacksaw blades can be a lot safer, and of course either of these types of tools require safety glasses.

Thanks again, very helpful!
JD