Best tool for.....

[kpdalton]

Can you guys recommend your favorite tool(s) for cutting into painted sheet metal which may be pretty delicate or a small area? Like say, putting vents into a dash. I know a few ways to do it but I'd like to work smarter not harder and the right tools make all the difference in the world.

[youngrodder]

Originally Posted by kpdalton

Can you guys recommend your favorite tool(s) for cutting into painted sheet metal which may be pretty delicate or a small area? Like say, putting vents into a dash. I know a few ways to do it but I'd like to work smarter not harder and the right tools make all the difference in the world.

I had to do just that with my truck during final assemble. I would recommend using painters tape to protect the area around where you cut. If you have room cut with a jig saw or similar tool. This will help to keep the heat down. When you remove the tape work it towards the hole you just created. This will help from catching an edge and peeling your clear or paint.

I tried a hole saw and it didn't go well. I had to fix my dash panel as the hole saw walked and created a bigger hole than I needed. Learn from my mistakes

Good luck
Marc

[kpdalton]

Yeah that was one option, a jig saw, but then thought of drilling several holes within the painters tape, then jigsaw, and then using a dremel to file down the remains. But that seems like a lot of work if there is a tool that easily cuts small areas.

[youngrodder]

That's another option. Basically it sounds like you are thinking about it right. It is scary as hell to cut into painted metal. That is my lesson learned...complete the fab of the build 100% before it goes to paint.

Marc

[chev3600]

Maybe a mini air saw? Cuts nice and is pretty controllable, as long as whatever youre cutting doesnt flex much.

[OrrieG]

Ax.....no use painters tape and a small air saw with small blade. Much more control than a regular jig saw and will cut smaller radius. Dremel for really small stuff that require enlarging or smoothing. Here is the last hole I cut with my air saw. top at the magnets is radius too. It does not heat up the metal like a cutoff wheel.

[1project2many]

A nibbler can be good, too. There's no raised metal from the return stroke to deal with. Also, there's a type of putty that's great as a heat sink. I've used it before but I can't remember what it's called now. It's handy to have around for jobs like this.

[torchlight]

I agree with 1project2many. Look into using a nibbler and then you can use a dremel with a grinding bit to smooth the cut from the inside.

[Kabwe]

I like to use tape and draw the pattern on top of the tape, drill small access holes and use a body saw. I believe its the same tool that OrrieG is talking about. It looks like this.

[OrrieG]

That's it BAM...

[solidaxel]

Originally Posted by Kabwe

I like to use tape and draw the pattern on top of the tape, drill small access holes and use a body saw. I believe its the same tool that OrrieG is talking about. It looks like this.

I like that also from HF except you need two, as one will stop in the middle of a cut !!
Just make sure you have GOOD new blades, with fine teeth.

[Kabwe]

Originally Posted by solidaxel

I like that also from HF except you need two, as one will stop in the middle of a cut !!
Just make sure you have GOOD new blades, with fine teeth.

You are correct about the HF one, but I bought a Ingersoll Rand one after that and I never had that stop in the middle issue again.

[OrrieG]

A drop of machine oil everytime you use an air tool helps with that problem.

[Kabwe]

Originally Posted by OrrieG

A drop of machine oil everytime you use an air tool helps with that problem.

I oil my air tools before I use them but I still had the issue with the HF air tool. I don't have that issue at all with the higher end Ingersoll Rand one. All in all the HF tool worked okay other than being a nuisance at times. I used it until it went out on me, but I did go higher end when I replaced it. I did the same with all the tools I use a lot and I used that air saw a lot.lol For projects every now and than I would get the HF one but if you are going to use it as a work horse I would step up the game.