Originally Posted by Wile E Coyote
Parallel to the forstner idea...
A suggestion given to me locally is to take a 6" piece of 3/8"OD steel tubing (steel hydraulic tube stock) and sharpen it similar to the rim of a forstner bit. Chuck it in the drill press and run at low speed. Then use something like Dawn dish soap to lubricate it while slowly cutting the rubber cover. Once through the outer rubber layer, peel it off like a sticker from its backing. Then finish drilling the plastic/fiberglass or ??? with a brad point. Tedious but it just might work.
Gonna think about this a little more before I commit to possibly tearing up a perfectly good stock.
For those who may want to do the same, the above worked nearly perfect.
The cutter should be a sharp as possible. Should I find the need to do it again, the only thing I would do differently is to run the drill press a little faster; I ran at my lowest speed - about 250rpm. The holes cut are neat, clean and sharp.
Once the rubber 'skin' was cut, a HS twist drill was used for the fiberglass base layer.