I know this is a step everyone goes through, but thought I would post my results and tools used. I initially was going to try and use the sawzall the manual shows, but quickly followed other people’s advise and used my handheld Dewalt cut off wheel tool. It made nice accurate work of the tab. The 5/8” hole chase was easy, slow and steady. I used a new sharp bit with some tap oil very so often, cut through like butter. The oil keeps a lot of the aluminum shards clumped up which is nice for cleanup. I finished off de burring with a handheld Milwaukee band sander. Love this tool, makes quick work on metal cleanup.
My problem of the day was a stubborn wheel stud (one of the new ones) it just didn’t want to go in and ended up recking the threads. So had to order a new one. All the rest went in with no issues using the washer and lug nut method.
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