Did the motor stall or just the spindle? If the belt is slipping on the spindle, You could just need to adjust your belt tension, and try slower feed rate. I've got a little grizzly benchtop drill press that will cut surprisingly big holes, if you let the bit feed itself and try not to over-do it. I modified it a bit by adding a machine bolt belt tension adjuster, so the motor stays where I adjusted it to.
On the other hand, you could use the drill press to make a template, and cut the hole out using your router. Little louder, little messier, but probably a lot quicker in the long run.
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Doug
1 John 1:9
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