Step 4: Making the Cuts
Now that you've traced everything out, it's time to start our cutting. For the circles, I've chose my holesaws based on the bottles I'm using, and going to use a drill press for this. Since it's especially important that everything be properly lined up, I'd recommend this to everyone attempting this project. The drill press will make sure my cuts are even and in line without wandering out of position.
Wear proper eye protection. I'm sure I sound like a broken record, but no one wants a metal sliver in their eye!! With that said, this is messy, so I'd make sure you're working in an area that metal shavings won't be an issue.
I'd recommend placing the aluminum on top of a piece of wood, then clamping them down to the drill press bench to make sure they won't move. When cutting metal, make sure to run your drill press at a higher RPM and if you don't have cutting oils, use water to keep the temps down. It will make a world of difference. Now you're ready to make your 20 cuts to the aluminum. This one is time consuming, but pretty simple. Move at a speed that feels comfortable, as you don't want to crack your bit.
When cutting the acrylic, you want to run your drill press at a lower RPM. This will prevent the acrylic from melting. If it starts gumming up your saw, your cuts will take much longer, and you can risk cracking the acrylic.
I've intentionally left the exact measurements out of this, but I'll include the exact measurements for my layout at the end.