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Old 09-08-2007, 06:53 PM
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Help--Need to Cut a hole in Firewall

Hi Guys:
I am replacing the bulkhead plate on my firewall( this is the aluminum plate where the A/C and heater hoses attach to the firewall) Problem is, I recently had the firewall painted--dummy me did not change the bulkhead at that time. Now I don't know what would be the best way to cut the larger hole that I need for the new bulkhead plate without scratching the paint or causing it to peel off. Is there a type of hacksaw blade that would make the job easier? Would a coping saw blade work? Or is there a power tool that would do the job? Your help would be greatly appreciated.

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Old 09-08-2007, 07:00 PM
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Quote:
Originally Posted by trifivefan
Hi Guys:
I am replacing the bulkhead plate on my firewall( this is the aluminum plate where the A/C and heater hoses attach to the firewall) Problem is, I recently had the firewall painted--dummy me did not change the bulkhead at that time. Now I don't know what would be the best way to cut the larger hole that I need for the new bulkhead plate without scratching the paint or causing it to peel off. Is there a type of hacksaw blade that would make the job easier? Would a coping saw blade work? Or is there a power tool that would do the job? Your help would be greatly appreciated.
Why not just use a air powered cut off wheel ?
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Old 09-08-2007, 07:50 PM
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is the hole going to be covered by the new plate and by how much. U need to
be careful to lay out your cut line smaller then the plate. use a hole saw at 2 opposite corners so tha the edge of the saw is going to cut on the cut line u wnt. go slow so as not to create much heat and tke your time . a little watrer sprayed on the fire wall if drilling from the front is ok.don't get the metal hot.just trigger the drill and don't use a brand new saw as it will dig in to much and u will lose control and possibly mar up the wall. drill a pilot hole first then the hole saw. after u have the 2 opposite corner holes now u can use a hacksaw blade by hand to cut on the cut lines and should not create much heat. it is difficult to keep the blade straight . if u don't have the experience with the tools u should get some practice on scrap or make a friend that works with tools for a living. A rod shop should be able to dom this for if u want.
They would probably use the cut off wheel as suggested earlier.
hope this helps
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Old 09-08-2007, 09:22 PM
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to cut a hole

had a similar problem/ordeal on my sedan delivery....what i did was mark off the bulkhead on the firewall, used masking tape to cover the area marked off. this allowed the holesaw i used to cut through while keeping the paint from peeling....worked for me...might for you...i cut through the tape and the firewall from the outside to the inside. of course the other ways described above work also....more than one way to skin a cat!!!
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Old 09-10-2007, 10:19 PM
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Help--Need to Cut a hole in Firewall

Thanks, guys for the helpful suggestions. I certainly will take it slow whether using the air tool or the hacksaw.
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