A common question is: How you make a round hole in a square with AC3D? The boolean plugin works with 3D objects only, so cannot be used in this case.
This movie shows one of the possible methods.
The processes used:
- create an elipse (which is a polyline surface) - a single click will create a regular circle
- set the surface type to 'poly'
- select Surface->Make-Hole
- in Vertex selection mode, select outer vertices and 'squeeze' the vertices to line them up.
http://www.ac3d.org/ac3d/forumpics/roundhole.htm
The result is easily extruded to create a box with a round hole through it.