[DanTwoLakes]

I need to cut a precise opening ( way more precise than the lines in the picture!) for the new stereo I'm putting in my '48 Chevy coupe. I'm thinking of using a mini air cutoff tool to do the job. Can any of you think of a better way to do this? I don't mind buying the right tool for the job. Thanks.

[Shelby1]

I use a mini air reciprocating saw with a fine tooth blade but It's kind of expensive for a one shot deal but does a very good job ,very easy to control and no sparks flying around.
The cut off wheel is good if you take precautions , tape off everything around it and cover everything in the interior so sparks won't burn anything. And make sure you protect your window glass ,hot metal sparks will melt and stick to glass.

Good Luck
Kenny

[speedydude]

For that I would probably use my Dremel with a HD cut-off wheel. Some sparks fly but not too bad. I would still tape everything off like Kenny said. Then I would finish the rough edges with a tungsten bit to get it precise, though I would think the frame cover should hide some.

Precision GOOD, sloppy BAD!!!

Mini recip saw???? Dang, time for a new tool.............

[j-jock]

A very clean and accurate method of cutting the opening, would be to use Greenlee square punches. They are a little pricey, but they are unbeatable for accurately cutting through sheet metal. This method would require drilling accurate pilot holes for the bolt that connects the cutter with the die.
Another possibility, would be to use a hand nibbler to expand an opening that has been cut just inside the final dimension.
Bob

[79C10]

Not sure of how thick the steel ison a '48 , but I've used straight line sheet metal shears with fantastic results before. Cut the top and bottom lines , then fold the 'tab' back out of your way.
Best of luck with it , whichever method you use.
Remember though - Once you hack , you can't go back.
Mike

[RPM]

What about a fine tooth jig saw blade in a jig saw? If you don't want to take a chance of scrathing the paint around the hole lay down some tape for the jig saw to ride against.

[poncho62]

Originally Posted by 79C10

Not sure of how thick the steel ison a '48 , but I've used straight line sheet metal shears with fantastic results before. Cut the top and bottom lines , then fold the 'tab' back out of your way.
Best of luck with it , whichever method you use.
Remember though - Once you hack , you can't go back.
Mike

Actually, you could go back using that method.....just fold the pieces in and leave them there....If you wanted to go back to stock, you could unfold them and weld them back in place........

[DanTwoLakes]

Originally Posted by RPM

What about a fine tooth jig saw blade in a jig saw? If you don't want to take a chance of scratching the paint around the hole lay down some tape for the jig saw to ride against.

That would be great if the top of the opening didn't have to be so close to the chrome. I need something that can get into a tight place. Maybe I should mount the radio in the grille just above the chrome?

[poncho62]

The chrome must be removeable?......I know, more damn work........

[DanTwoLakes]

THANK YOU!! Poncho, you're brilliant! I just went and checked, and the chrome piece in question is about 16" long and is attached with two spring washers. It will be a piece of cake to get out, and a lot easier to cut the hole. This is why this bulletin board is so great. You really old guys are so smart.

[Shelby1]

OLD GUYS????????? how did he know? I can't find no camera on this thing.
Later
Kenny

[DanTwoLakes]

Kenny: I was referring to Poncho who I know is 55 because it shows on his profile, but if the shoe fits................. BTW, in case you didn't notice, I'm 3 years older than Poncho.

[poncho62]

Originally Posted by Shelby1

OLD GUYS????????? how did he know? I can't find no camera on this thing.
Later
Kenny

You don't know what "powers of the internet" us moderators possess...... ...........Spooky, isn't it?..........

[DanTwoLakes]

Originally Posted by poncho62

You don't know what "powers of the internet" us moderators possess...... ...........Spooky, isn't it?..........

Think we should tell him about the web cam embedded in the Hotrodder's Bulletin Board software, and the reverse imaging emanating from his monitor glass?

[Dqracer]

Shelbi's suggestion for the recip air saw would work the best,, cut just inside your lines ,then sneak up on the final opening size with a good flat file.