I wasn't sure if this was the appropriate area or not but I am looking to add something to the outside of my truck. I want to cut a 3 inch hole in my fender. Why you ask so my snorkel can fit through. I was wondering what you guys thought was the best way to do this.

 

As long as your sure of what you are doing just take a holesaw to it. Make sure of where you want the hole to be, then double check. Take a centerpunch and make an indent where you want the center to be, and then drill away SLOWLY. Keep the drill perpendicular to the metal so the holesaw contacts the fender at the same time all around

 

Would it be better to use the hole saw from the inside of the fender or the outside? Does this matter or should I just do what will be easier.

 

id say from the inside out, cause if you do it from the outside, the fender will want to push in and probably leave a nice dent

 

http://www.harborfreight.com/cpi/cta...itemnumber=113

This would give you better results.

 

You shouldnt need enough pressure to put a dent in the fender. Let the drill do the work. Although I wasnt thinking of it with the fender off either (assuming the fender would need to be off in order to work from the inside)

 

I would go from the outside and lay masking tape down and drill through that so not to tear the paint up as bad. Itz supposed to help.

 

I was thinking that a saw would give me better results granted that means I have to be more careful.

Looks like that saw is about the same as a good hole saw too. Too bad I don't have an air compressor.

What do you guys think about a sawzall.

Thanks for all of the input btw.

 

Stay away from the sawsall Bryan, most likely that will give you an imperfect hole, and you'll have a bit of grinding to do to make it look round. Also, if the blade catches in anyway its going to pull the metal of the fender up and down and dent it pretty good. I think the hole saw is your best bet, along with what Luke said about laying the tape down to preserve the paint.

 

Yup hole saw it is along with the tape. I should have this project started sometime in the next couple weeks...maybe months...eventually.

I have to get two things out of the way first, a new alternator, and a skid plate when these things are done a snorkel will be on the way. Before thanksgiving will make me happy. But the sooner the better.

 

If you use a sawzall and really fine toothed blade it should be ok. Id make the hole smaller than needed and sand/grind until its perfect. IMHO, I dont think the hole saw is going to be a good idea.

Another way to do it is drill a bunch of holes making your circle and trimming it up.

 

Why wouldnt a whole saw be ok?

Hes cutting a hole in sheet metal.....there is a drill bit in the middle to keep it in line....

Will leave a nice round hole....use a dremel to clean up the metal, and then slide the snorkel through...

DO NOT use a sawzall at all....IT will grab and chunk it everywhere, let alone it will bend / chip the paint to hell..

Rocky

 

^ beat me to it... hole saw and call it a day, not to complicated at all.... just make sure its sharp....

 

I for see the same thing you do about the sawzall, I just see it as the hole saw doing it. I guess we have had bad dealings with them.


Either method used you really should mask off the work area and maybe the whole fender.

 

I will mask off a large area and plan on taking it very very slow. This is something I am going into tentatively. Like I said it is on the back burner right now but I am definetly going to get to it in time. Right now I have to get this skidplate worked out.

 

Just use a smaller hole cutter, and dremel it out to the right size so its not a huge hole when you clean up all the metal

Rocky

 

thats what I would do. The dremel I have is air powered and the bit is carbide. It eats it pretty fast.

 

I still say a 3" hole saw but if you really don't wanna do that then use a jigsaw with the finest tooth metal blade you can get. It will be much easier to deal with than a sawzall.