Help wanted -Bodywork Mods.

[Bullman]

Can anyone advise the best,neatest, way of cutting a hole in the bodywork for the larger 4 into 1 exhaust manifold.I have a 1700 x- flow supersprint with the 4 into 2 into 1 manifold at the mo but would like to convert.What tools are required,what is the procedure,could any one send me a template of the shape to cut out .Thanks in anticipation.Bullman.

 

Bullman

[captain chaos]

The best tools are either a drill attachment called a 'nibbler' or some Monodex cutters. I've got the Monodex cutters as recommended by Arnie and they are excellent. Cost about £25 from a reputable tool stockist.

[Red SLR]

I am also interested in this, so basicaly you just cut the metal away with cutters?????

 

I have looked at the area and the metal looks very thin so should not be too hard to cut with cutters.

 

Does the paint suffer damage?

 

X777CAT

[tony pashley]

An alternative way to get lovely clean 'corners' -

work out the shape you want to cut away and its position; cut the corners with a large-ish Q-Max punch (the things you use to cut holes in instrument panels and dashboards - unless you ran out of things to buy and got a carbon dash); join up the corners carefully with a hand nibbler; finish the 'straight' cuts very carefully by hand - or very very very carefully with a drill motor and abrasive flap-wheel. Care is the watchword.

 

Edited by - tony pashley on 7 Oct 2001 10:16:16

[Jason Plato]

I used a jigsaw with a fine tooth and finished with a drill abrasive flaper wheel thingy when I cut a hole in my bonnet.

If you masking tape the area and be VERY carefull it works well with no distortion to the panels .

 

dave

[c7kjt]

Just gone 4:1 myself. I used a smallish drill bit to drill a series of holes, as close together as possible, to the approximate shape. I then used a small file to cut between the small holes, follwed by a larger file to smooth of the rough edges. Finished off with some emery cloth to get a really smooth and neat finish, and no paintwork damage.

 

My only other advice would be if you're thinking of using a Dremel then don't! it's all to easy to lose control of these things and end up with a hole much larger than you originally intended.

 

Kevin Thomas

kevin.thomas@bigfoot.com

www.7gallery.co.uk

 

[JP]

This is a conversion I am planning. Is a there a template for this hole? If there is, is it centred over the existing small hole or is it eccentric?

I looked very closely at lots of cars at Caterham the other day and there was little consistency - these holes seemed to be all over the place.

James.

[Casbar]

I did this conversion last year, and tried several different methods. The one that def didn't work was the Dremel.

 

In the end, I used a rounded pair of tin snips, finished off with emery cloth and a fine rounded file.

 

Drilling small holes around the approx shape is also a good solution.

 

As for the shape (template) use the Mk 1 eyeball and suck it and see approach!!

[Dave H]

When I fitted my Zetec earlier this year James Whiting supplied a template for the 4 to 1 exhaust hole. Give him a call. Unfortunately I think I chucked mine once I finished with it.

 

Dave H

[captain chaos]

I take it that most of you have cut holes into painted panels and had no problem with the paint cracking around the cut line?

[captain chaos]

How degrading...I've just become a windbag!

[Dave H]

If you use a Mondex or Nibbler you won't bend the ali when you cut it - its the flexing that cracks the paint. Don't use snips because they will flex (or bend) the area round where you are cutting.

When you file off to achieve a smooth finish be careful not to be to heavy handed, and use a fine toothed file, or you can catch and crack the paint with it.

 

Dave H