jp7 Posted December 3, 2002 Share Posted December 3, 2002 Hi all, at some point i've got to get a bigger hole cut for my slr exhaust. If anybody who has been down this route could give me a few pearls of wisdom on the subject, like how did you get the shape,what tools etc, i'd gratefully appreciate it. cheers Andy Link to comment Share on other sites More sharing options...
scooby dooby doo Posted December 3, 2002 Share Posted December 3, 2002 a flapper wheel works well, tin snips for any big chunks. HOOPY 500 kg R706KGU Link to comment Share on other sites More sharing options...
stevefoster Posted December 3, 2002 Share Posted December 3, 2002 We used a round punch nibbler and a 22000 rpm air grinding tool on Phil's. Bit OTT, tin snips and a flapper wheel or round file would do. We had to cut and then offer up the pipes time and again to get the hole to suit. Mail me if you want some pics of him doing it. He made me do all the nibbling. Could barely watch as his baby got cut up. He made a nice job of it, as he does with most things.... /Steve My racing pics, 7 DIY, race prep. Updated often here Hants (North) and Berkshire area club site here Edited by - stevefoster on 3 Dec 2002 12:06:42 Link to comment Share on other sites More sharing options...
scooby dooby doo Posted December 3, 2002 Share Posted December 3, 2002 A file tends to damage the paint - the flapper wheel is actually faster, less noisy and gives a better finish. HOOPY 500 kg R706KGU Link to comment Share on other sites More sharing options...
Mick Day Posted December 3, 2002 Share Posted December 3, 2002 I used a Dremel with a carbide cutter at high speed. Again had to offer up the headers time & time again to get a nice fit. Finaly used several grades of rotary abrasive to polish. Mick Link to comment Share on other sites More sharing options...
Area Representative Tin Man Posted December 3, 2002 Area Representative Share Posted December 3, 2002 Andy I got Caterham to send me a nice cardboard template with the exhaust. I marked it out with a eye liner pencil & used plenty of masking tape to protect the body. I cut the hole to the pencil line with a dremel & used the tape to support the peice I was cutting. I then finished it off by using a file to remove the aluminium to the out part of the pencil line. Just take your time. All the best. Link to comment Share on other sites More sharing options...
jp7 Posted December 3, 2002 Author Share Posted December 3, 2002 Thanks for the replies. If i get hold of a template, how do you work out the position? Also if i went down the 'grind a bit and see' route, could i use a flap wheel for the whole lot, and not bother with the tin snips? cheers andy Link to comment Share on other sites More sharing options...
Mole Posted December 3, 2002 Share Posted December 3, 2002 I got a cardboard template from Caterham as well. It was nicely shaped to fit over the top chassis member and against the Dzus fitting for the nosecone so it was possible to position the whole thing in exactly the right place. I put masking tape where the cut was going to be made, marked and then drilled a row of very small holes just inside the line, used a dremel to finish off. I echo Tin Man's advice - the secret is to take your time. The more impatient you get, the more likely you are to make a mistake . Where are you - I still have the cardboard template in the garage if that's any use 🤔 SV 52 CAT - the Mole is flying Link to comment Share on other sites More sharing options...
jp7 Posted December 4, 2002 Author Share Posted December 4, 2002 Hi mole, im in lightwater, surrey. just off junction 3 M3. Where are you? Andy Link to comment Share on other sites More sharing options...
Mole Posted December 4, 2002 Share Posted December 4, 2002 Andy - you have e-mail (I hope) ❗ SV 52 CAT the mole is hibernating Link to comment Share on other sites More sharing options...
Midnight Posted December 4, 2002 Share Posted December 4, 2002 I also used a flapper wheel to get a nice smooth exhaust apperture. Another advantage is that its fairly smooth to use. I would recommend either doing this job outside or keep everything covered up (including your nose, and mouth) as the aluminium dust gets just about everywhere. Link to comment Share on other sites More sharing options...
stevefoster Posted December 4, 2002 Share Posted December 4, 2002 Andy, I'm in Bisley! Do you go to the Hants (north) and Berks Area meetings? /Steve My racing pics, 7 DIY, race prep. Updated often here Hants (North) and Berkshire area club site here Link to comment Share on other sites More sharing options...
robmar Posted December 5, 2002 Share Posted December 5, 2002 Steve - yes he does, Andy has a very shiny all silver caterham Andy - I have some flap wheels left over from when WIll SPIN butchered the side of my car if you want them, can bring them over friday 🤔 also I can chat about how we did my hole cutting rob Link to comment Share on other sites More sharing options...
jp7 Posted December 6, 2002 Author Share Posted December 6, 2002 Hi rob, that would be very nice. I'll bring those ignition leads. cheers andy Link to comment Share on other sites More sharing options...
jp7 Posted December 7, 2002 Author Share Posted December 7, 2002 Hi Mole, emailed you and got it bounced back. It would be great if you could post up the template. If you email me with your phone no. i'll call you to give my address. Just to check, the template is for a k series SL-R 4-2-1? Cheers Andy Link to comment Share on other sites More sharing options...
robmar Posted December 7, 2002 Share Posted December 7, 2002 Andy - forgot the flap wheels, so will drop them over some time, send me an email with your address also am happy to give you a hand if required 😬 rob Link to comment Share on other sites More sharing options...
Gary-Cornwall Posted December 9, 2002 Share Posted December 9, 2002 John, what are you doing with an eye liner pencil 🤔 Link to comment Share on other sites More sharing options...
Area Representative Tin Man Posted December 10, 2002 Area Representative Share Posted December 10, 2002 Can`t say 😳 😳 Link to comment Share on other sites More sharing options...
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