Look up at car audio fabrication on YouTube, the new hotness is recessed wire mesh.

Some good ideas there, but not quite what I'm looking for. Thanks Jesse, will put this in my memory bank for later use.

Yes, This can be a tedious process! This is what we've always done. We create a template out of clear rear plastic window curtain with all the holes correctly marked and punched thru. Cut a piece of black waterproof panel board to the same design and size ,then split in half. Glue your finish vinyl onto the split black water proof panel board. ( The split board gives strength to the vinyl but still allows to punch thru easily) Mist glue on only the template plastic, place on top of the vinyl/panel board piece. ( The misted glue allows the template to lightly stick in place) Then mark all the holes with a china marker. Lay onto a flat cutting board and punch away.

I have always done it one hole at a time. With the advent of the CNC perf machine I will be sending them out from now on.

Thanks everyone..That sounds like it will work Eric, I'm going to make the template. Making it once is a lot better than each time. Thanks again to everyone.

Sounds like a LOT of work, why not just buy some perforated vinyl and use it?

I agree with @Steve Ingram. These days, you can have the vinyl professionally perforated for you.

Hydes Leather, for instance, will do custom perforation. You can have a roll of black vinyl perforated the way you like and just store it for later use. It'll save you time when you need it later.

I'm guessing Hal is talking about those panels which have speaker perforations in the middle of an otherwise plain piece, such as on Mazda MX5 / Miata seats with the in-built headrest speakers, or on some door panels. In those circumstances I wouldn't think you could have a roll perforated to your needs because you'd never know how much plain vinyl you'll need surrounding the perforations for that particular job. Unless you do a lot of one particular car and can have the perforated areas spaced to suit.

I was talking about a plain panel with a speaker in the middle...What Eric suggested will work although I haven't made the template yet. It will still be a slow job, but will look custom when done. I've seen it done, just didn't know the best way to go about it.

Hal. These are some of my templates I’ve used. Try printing them and glue onto a piece of vinyl or clear plastic. Hope this will help.

I'll do it..that's exactly what I was talking about...Thanks