Fitting a fatter exhaust - sideskin hole enlargement

[AntonyH]

If I were to be contemplating swapping my standard single-tube-primary K-series exhaust for a 4-2-1 system, and therefore would need a bigger hole in the side skin, how difficult is it to enlarge that hole neatly, and without trashing the shiny paint work?

Is it the sort of thing that a ham-fisted cludger can do with a suitable tool, or something you'd only entrust to a seasoned professional?

[stuart147]

Hi Anthony.

When Powerspeed fitted mine, they carefully offered each primary up in turn making the hole bigger as he went. He did give me the option to look away.The guy used a nibbler that was air driven. I can send you some photos of the job being done if you give me an E-Mail address.

Stuart

 

[Jonathan Kay]

There are several reports in the archives of nibbling and flap-wheeling and Dremelling. Most seem happy but say it takes a long time to get right.

Jonathan

[TomB]

I've had to cut a small hole (10p size) in one of my rear damper turrets. I have a rotary burr bit for my Dremel and its devoured the Ali material. Something like that could be a way to open up the hole. 

[AdamQ]

This is something I've had to do on occasions and it's always something I put off out of sheer terror.  However, it's not so bad - mask with a few layers of masking tape or cardboard for acres around for the almost inevitable (in my case) slip and then a Dremel with a burr tool as suggested followed by a flapper wheel.  

[John Cousins]

I had a Powerspeed 4-2-1 fitted to my Roadsport on Monday - I was definitely very happy to leave the cutting and fitting to the professional

[Nick Bassett]

Hi Anthony

I fitted a 4-2-1 to my car about 18 months ago - I can send you a template to use if that helps?

It's quite straight-forward if you take your time and work methodically - also treble tape the paint work around where you are cutting to avoid any damage to the side-skin. I used a Dremel type tool plus a number of small files & emery paper to achieve a lovely smooth finish. The metal skin is very thin & soft, so easily workable.

Back-breaking work though - I had to work in a tiny garage and was in quite a bit of pain the next day!

PM me with your mobile number if you want to have a chat!

Cheers

Nick

 

[AntonyH]

Thanks all.

The pictures Stuart sent were enough to pretty much put me off the idea as a DIY job (he did a great job on his, I should say!); Nick's mention of "back breaking work" in a "tiny garage" has definitely sealed the decision that I'd pay someone else to do it - my garage also isn't huge and my back is dodgy enough at the best of times.

[Nick Bassett]

Sorry I didn't mean to put you off! It is hugely rewarding to do yourself and isn't too difficult either! I wouldn't rule out doing it yourself and if you spread the work out over a few days your back wouldn't suffer as much. If you were closer I'd offer to help you out!