Lateral-g Forums - Roadster Shop 2nd Gen Camaro Build

Quote:

Originally Posted by dave96dcm (Post 503036)

I have a kinda dumb question but I gotta ask, what do you use when cutting cutouts like next to the headlights on the body? A air powered reciprocating saw? Cutoff wheel? You just have such clean edges and nice cuts I'm curious your method.

I know you asked RS === but I thought I might help you thinking thru a "cut out" like this.....

I'd make a template (paper) of what I thought I wanted...

I'd tape it on the area and stand back and live with it for awhile....

If I decided it's what I wanted -- and AFTER I'd thought thru all the things it would entail - such as "what's behind" -- "whats going to interfere" -- "what needs to be moved/relocated" etc....Then I'd proceed in taping securely after squaring up and making sure they were spot on for location - and being plumb etc on both sides...

Then I'd mark where I needed to use my Haugen Roto Broach - and what size I needed to make the 4 "corner radiuses"....

I would then proceed to tape a straight line to connect each of the 4 (now 4 round holes).... corners and use a cut off wheel to make that cut -- or perhaps a body saw... or maybe even make a larger "rough cut out" in the piece and then trim with a hand tin sip if I could get to the work (might need to use -- left - right - and straight snips).

Then I might clean up the edges with a good old fashioned hand file -- or a 3M disc on a couple different air tools....

In other words ----- to do work like this takes lots of planning ---- skills ---- and tools.... and there may be no two guys that would do it exactly the same way.

:D