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Old 09-30-2016, 07:05 PM
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Making Oval Holes In Fiberglass Fenders

I'm in the process of installing after-market '39 Ford tail-lights in Wescott fiberglass fenders. The mounting stud holes are drilled, plus I've used a hole saw to to cut out the upper section of the oval tail-light housing. I'm now to the point where I need to expand the hole to the required oval shape.
Question: Should I use a Dremel burr to expand the cutout to the required shape, or would a jig-saw be a better tool? Also, any other tool suggestions?
Thanks for all input......

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Old 09-30-2016, 11:33 PM
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I'd use the burr just for better control of the very final trimming. But I'd want the 1/4" kind of burr bit rather thatn 1/8". The Dremel drums would work pretty good, I think.
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Old 10-01-2016, 02:31 PM
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A file and doing it by hand works real well, doesn't take too long, and less chance of "Dang It!".
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Old 10-01-2016, 02:42 PM
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An air saw would work and the blades are really fine so you have good control
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Old 10-01-2016, 02:57 PM
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I have used a wood rasp to good advantage to finish fiberglas before.
https://jet.com/product/detail/96ac7...EH0A&gclsrc=ds
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Old 10-01-2016, 02:58 PM
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Yep; the air saw would probably give me the most control, but, unfortunately, I have no compressor in my home shop.
Thanks for all your input; I'll probably give the burr a shot, with a file for fine-tuning.
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Old 10-01-2016, 08:32 PM
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By hand for sure or a cylindrcal sanding tool in a drill. DO NOT use a jig-saw, you risk cracking the glass, especially if it is old.
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Old 10-03-2016, 12:43 PM
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Quote:
Originally Posted by crdnblu View Post
I'm in the process of installing after-market '39 Ford tail-lights in Wescott fiberglass fenders. The mounting stud holes are drilled, plus I've used a hole saw to to cut out the upper section of the oval tail-light housing. I'm now to the point where I need to expand the hole to the required oval shape.
Question: Should I use a Dremel burr to expand the cutout to the required shape, or would a jig-saw be a better tool? Also, any other tool suggestions?
Thanks for all input......
A round file called a rat tail file. For bigger holes dremel has a rotory cutting tool ,it looks like a drill bit but it cuts sideways or even a trim router for trimming counter tops.

Last edited by deadbodyman; 10-03-2016 at 12:50 PM.
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