Best way to cut for AC Vents?

[nitrosport_5]

Ive searched and really have not found a good way to get the correct hole for the factory AC Vents. I already have grafted in an AC firewall. I dont have a donor truck to take templates off of, so at the moment i am sitting with the factory ac vents, and a dash with no holes. Thanks in advance.

[MARKDTN]

Measure 2-3 times cut once.

I used a drill then a jigsaw.

[TobyArnot]

http://www.vintageair.com/INSTRUCTIO...0A%2012.15.pdf. Go to pg. 23. Hope that helps.

[Lattimer]

I used a holesaw for the round vents and a drill and a dremel with cut off wheel for the center. I cut them small and then ground them with the dremel to get them to size.

Mine are repro parts from Classic Auto Air. The install manual for the system has a template for the center: http://www.classicautoair.com/?q=67_..._Chevy_AC.html

[dznucks]

I tried several options when i did mine and found the best thing to do is layout the hole location and scribe the circle on the dash panel. then drill a hole inside the circle and use a pnematic air saw cut the circle out. You probably wont be able to cut the entire circle at once, but you can cut peices out at a time. When you get close to your scribed mark, use a grinder like mentioned above to get to you final hole size.

I bought a hole saw for this, but it kept jumping and grabbing chipping the paint.

[Lattimer]

Originally Posted by dznucks

I tried several options when i did mine and found the best thing to do is layout the hole location and scribe the circle on the dash panel. then drill a hole inside the circle and use a pnematic air saw cut the circle out. You probably wont be able to cut the entire circle at once, but you can cut peices out at a time. When you get close to your scribed mark, use a grinder like mentioned above to get to you final hole size.

I bought a hole saw for this, but it kept jumping and grabbing chipping the paint.

I went one size smaller on the holesaw, so even though it didn't cut real clean it didn't matter because I had to grind the hole to finish size anyways.

Did it last weekend, so its still fresh in my mind.