went for a Dremel and used a coarse toothed cutting wheel for the rough cut inside the template. Once the hole was large enough we placed some clamps on the cut edges to damp vibrations, and then used a high speed cutter (no. 134 I think) to approach up to the final line. The edge was finished off with a metal file.
After practicing on a piece of aluminium sheeting we marked out the side using the Birkin template over some masking tape and cut away.
The end result looks fine and the process was repeated for the petrol filler cap, as we've gone for an after market one. Once we'd stripped the chassis of fuel tank and fittings, given it a quick clean up and taken a few pics, it was onto a trailer and off to the painters.
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