hole saw size for A/C dash vents

[69Tom]

Can someone please confirm that a 3.5" hole saw is the correct size for the stock A/C dash vent holes? Just ordered one online and want to make sure I'm getting the right one.

Thanks

[john]

I believe the 3 1/2" would be too large, the holes are about 3 1/2"x4 1/2" on a flat surface. With the curvature of the dash I would use a smaller size to start with.

[Lanman1972]

I used a template from someone here. Then I used a cutoff wheel to cut the shape. I will pm you if I find it.

[69Tom]

Thanks. I have the templates.

[Tdrcreyn4]

I'll tell you that the curve of the dash makes hole saws and cut off wheels difficult. I used a template to draw out the holes. After that I used a drill bit to cut the top half moon shaped hole as a starting point then switched to an air powered body saw (looks like a little hand held hack saw) to cut out the holes. Worked great and the holes looked like they were stamped at the factory. I had both sides and the middle vent done in less than 30 minutes........my two cents.

[69Tom]

I've read pneumatic saws are the easiest to use for this. However, air tools are out. Don't currently have a compressor to use.

[dfwright]

Where does one obtain the templates?

[72 tigger]

I cut mine with a hole saw- just take your time

[Acorn]

Tdrcreyn4's method is the best. But if you don't have the fancy tools you could try my redneck method. Trace the templet, then use what ever size drill bit you have and drill holes all along the inside perimeter of your templet, then use some good sharp tin snips and cut it out. Then file off any sharp edges. It's hard to make it look 'factory' this way but you can't tell once you put the vents on.

[sxh9057]

How do I get my hands on a set of the templates referenced? I am getting ready to add\cut vents in my 72 C10 so any help with where I could get them would be greatly appreciated!

[mosel70]

I just installed A/C in my '70 C10 which did not have factory air, got the A/c sys from Vintage Air. Their install instructions are online (link below) and have the templates on pages 22 and 23 for the cutouts for side louvers and center louver above the radio.

http://www.vintageair.com/GenIV%20sy...0A%2012.15.pdf

[BugzC10]

Originally Posted by 72 tigger

I cut mine with a hole saw- just take your time

X2...2.5" hole saw not 3.5", then use a file to clean up the edges and dial in the fit.

[sxh9057]

Thank you both!