Friday, May 05, 2006 at 12:33
What I did to reduce the stress and avoid damaging the guard.
1. have several cold beers standing by for immediate use after the hole is cut.
2. Use plenty of masking tape or gaffer tape to cover the area around the hole. That way if you slip it will help prevent scratches in the paint. I also taped thin cardboard over the top of the guard in the vulnerable areas.
3. I made up a template that I used to transfer the exact hole location on to the taped area. I marked the hole and the centre point on to the taped area.
4. Drill a pilot hole and
check under the guard for anything that might be at risk when the saw comes through. I had to pull the wiring harness out of the way and protect it with a sheet of ply.
5. cut very gently (light pressure) so the hole saw is less likely to grab.
If in doubt have a practice on your mates car first. Or cut a hole in a bit of scrap tin to see what will happen.
6. I used a 'flap disc' sanding bit (50 mm dia drum shaped with 160 grit sand paper flaps) in a hand drill to smooth out the edges of the hole while the tape was still on the painted area.
When you have cut the hole, stop and have a good look at how it all will fit while the tape is still on. Dont do what I did and remove all the tape then scratch the guard first with the file and again with the
snorkel while trying toi get it lined up (after a few beers).
Have fun
Geordie
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