Yes, those older cartridges are a X*&> to get opened. If you do tho they seem to go back together better. The plastic is not as flexible. I have a couple I got open without breakage. The fuji's I have come apart pretty easily. That sounds doable btw. It's crucial to keep the distance between the hole and the edge of the film. If you can make guides that are rigid it should be ok? The Surveillance film works well apart from the toughness of the base. After each roll I punch a few times through several layers of tin foil to resharpen the punch. If I make the next one out of plexiglas I think I can finish the edges and stuff to make it pretty slick to prevent scratches. Keep us posted of your progress. BTW which camera are you using?