Thanks you guys I really appreciate the comments.
This thing with the lightning holes came about when I was figuring out what I was going to do for the infra structure inside the frame rails to strengthen the frame up. I already made up my mind that any lightning hole I made I wanted some big radius' on them, not just welding in the tubing and putting a small radius from the weld. Not that there is anything wrong with that. It's a lot of work and I think it makes a part look real nice. I just want some big ones on this car. I have been playing with the idea of making some tooling I could slip inside of the different size material I'm using but it would take so may dies it would take forever. I have dimple dies but again they wouldn't work on say a piece of 2 X 3, you could get one side dimpled but not the other. Then I thought of just taking some 1/8" sheet metal and braking one side 90 degrees. With the pieces bent like that I could dimple both pieces then weld them together and I would have a piece of 2 X 3 with big radiuses. I gave up on that when I had flash backs on welding the stainless frame together, so that was out. That's how I came up with the idea of just machining the whole thing, drill an oversize hole and slip the machined piece in and weld around the hole and it's done.
Ken