I've found ProBoolean, as annoying as it can be, works the best for me. There's a script called Vertex Killer (http://www.scriptspot.com/3ds-max/scripts/vertex-killer) that'll remove all selected vertices with only 2 connected lines.... exactly like the ones ProBoolean loves creating for no reason. Run VertexKiller after…
Yep, proBoolean, floaters or chamfer'ed verts. Oh and... you can also cut in a a rough hole, then use the GeoPoly button in Graphite modeling tools to round out the poly making it circular. Illusion catalyst also has a free script available that does a similar function but works on loops instead of polys. It also makes…