> I need to cut a rectangular hole in the side of my cast iron wood
> stove, about 3"x5". I was thinking to drill holes for the corners and
> then try to cut with a sawzall. I'm guessing the iron is about 1/4"
Layout the hole, then drill holes along cutout line as close together
as possible, say 1/4 holes on 3/8 centers, then use a saber saw with a
bi-metal blade to cut out.
Finally, clean up edges with a 4" right angle grinder.
You will still have a pile of C/I dust, but it will be about as small