Any tips for how to do this while doing the least damage to the rest of the shell? I"m looking to put in real grilles on a GP38 to allow the sound from the tiny speaker I installed to better escape the shell. Thanks.
Don't know which scale or version you're working, but I would probably drill out the corners and use a sharp blade.
Here is the best advice I could give, from BLMA..... http://www.blmamodels.com/videos/BLMA.Fans.700Kbps.wmv
I used a small drill to go around the fan, then drilled a starter hole in the center of the fan, then drilled the fan out with I think an 1/8" drill bit. Cleaned up with a sharp exacto knife, then finished off with a round file. (I bought one just a tad smaller then the finished hole.) Then followed the BLMA instructions.
The video states to paint the fans white, but is this necessary? I would think the metal color would be more realistic.