Again I tried the pneumatic cuttoff tool. Again I was dissapointed. So I tried an alternate method. I used the sawzall to take small pie cuts out of the material. Sorta nibbling away at it until the hole was "mostly round" then finished it with a grinder. No pictures of the middle of the process here.......it was ugly. But once cleaned up with the grinder it looks fine.
I also took the time at this point to add a little extra weld to the UCA brackets. Nearly impossible to get that joint in there clean and it's tough to get the torch close enough for good puddle control and see what you are doing. The welds reflect that but they are fully penetrated.....just ugly.
On the other side I decided to try something different to see if the process could be sped up a bit and improve the quality. It involved a slightly more sophisticated tool than the sawzall.
Boy do I like this thing!
Where it took me nearly an hour to cut away the other spring pocket with the sawzall bit by bit, the plasma cutter did the job in about 45 seconds leaving a muuuuuch nicer hole...
