Chopping up body work

[CaptainJp]

One of the jobs I'm planing to do in May is to cut some holes in the bodywork.

I've ordered a dremel, but I need to buy a hole saw, what size did you guys use, was it a fine tooth or anything special?

Any tips to get a good finish?

[TuxMan]

50mm hole saw , metal cutting fine as possible , 40mm barrel sander for your drill to Finnish , long cuts all done with a 1mm cutting disc in a 4" angle grinder . Mark out with std masking tape and a black marker pen .





Tux

[andygtt]

CaptainJp said:

Any tips to get a good finish?

Don't copy this pic as the cut the other side of the panel is too large and looks to be in the wrong place and will introduce air the wrong side of the door shut

[TuxMan]

Looks ok to me Andy ??

[2.5bluenob]

I think to take onboard what Andy says would be a good move. Ive done this mode but cant help thinking that i should have made the rear holes smaller and maybe line the hole with some material to stop drag and also point the air in the right direction and not straight in to the door edge.
Steve

[TuxMan]

Because of the angle of the 1/4 panel I did do the door side cut as close to the outside edge as possible



Tux

[Adrian W]

I used a chain saw

Seriously I used a buzz saw (went through loads of blades)and a small air file.

[andygtt]

TuxMan said:

Looks ok to me Andy ??

That side is fine, It's the other side I'm referring to... If it also opens up to the wrong side of the door shut it will pressurise the door rubbers... Needs to be 20mm wide max and right against the outer edge IMO.