My redesigned board should be in next week, but since it's a direct swap for the other board, I see no reason to wait for it.
So I finally cut that scary, scary hole.
I was somewhat torn between putting the keypad underneath the door handle, and next to it. Most people I asked seemed to like it underneath, while I kind of preferred next to. Well, inside the door there is this "stuff". It kind of looks like metal painted on the inside of the door skin. For strength? Sound dampening? Something else? I don't know, but it made the door skin much thicker there (underneath the handle), so my decision was pretty much made for me.
Close up of metal "stuff".
Here are my practice holes. This allowed me to not only get used to cutting with my Dremel, but also work out the exact shape and size I needed to cut. I used the thin metal cutting disc for the Dremel. It worked well.
Here's the door with my template on it and taped up a bit.
Hole cut.
Looks a bit rough. (those marks below the hole are just dust)
The hole retaped, rough edges filed, and paint cracks sanded away.
Retaped and primer paint applied (to inhibit rust)
Dried and untaped.
Last shot of keypad and clip.
