Cutting Metal

[hobbes26]

So I'm happy because I have time on my hands to finally install my Kodas in the
doors of my EL (Civic) but lo and behold! - the Koda magnet is too big for the
sheetmetal hole. It won't fit in there! Argh...

SO - how should I go about this? Is there an easy way to cut the sheetmetal?
Special tools? I don't really wanna have to go and buy an expensive power tool
just to cut out about an extra 1/2" out of the two holes (one in each door)...

Are there any special bits for a Dremel tool that could cut the metal? I've already
tried tin-snips and it didn't really work...


Edit: I also should say that there's not much room behind the hole because there's
the track for the window that's pretty close behind there, so I don't know about
using a saw there...

[The_Ancient]

tin snips about $10 (that may be off I have not bought any in awhile) at walmart

[The_Ancient]

to add to that, probally the best to get is eith a Right or Left Cut off depending on which side your working on

[Steven Kephart]

I thought I told you about that issue.

When cutting metal, I always use an air saw. They are inexpensive, if you have air handy. Here's a pic:


But you are right that even after cutting, they will be about a 1/4" too deep. What I recomend is getting/making some rings for the drivers. This should prevent you from having to cut the doors as well since it's just the top part of the basket that doesn't fit.

Steven Kephart
Adire Audio

[hobbes26]

Argh... I already tried tin snips... didn't seem to work too well... And no air tools for me... I don't have a tank/compressor or anything like that.

I made 1" mdf rings already - that's not the problem - it's the fact that the hole in the sheetmetal behind it isn't even big enough to fit the Koda magnet....

What I think i'll do is try using the dremel with the cutting disc... it'll take a long time, but I think it should work just fine...

[The_Ancient]

Originally posted by hobbes26@May 11 2004, 11:47 AM
Argh... I already tried tin snips... didn't seem to work too well... And no air tools for me... I don't have a tank/compressor or anything like that.

I made 1" mdf rings already - that's not the problem - it's the fact that the hole in the sheetmetal behind it isn't even big enough to fit the Koda magnet....

What I think i'll do is try using the dremel with the cutting disc... it'll take a long time, but I think it should work just fine...

Striat or Angle Snips

Strait would be a Pain, Angles should not be though, Unless your a wussy :P :P :P :P

[hobbes26]

Actually now that I think about it - I think the ones my dad had were straight snips.... argh...

Okay, I'll go get me a pair of angled snips... and if that don't work... fall back on the dremel idea

[geolemon]

Well, rather than trying to cut out a circle, which would be a pain in the butt....
I'd suggest just making some radial cuts, maybe one every inch, maybe just going back a half inch or so, 3/4", whatever...
Then, you'll have several 'tabs' you can just bend back, into the hole - enlarging the hole.
This will work particularly well since your actual mouting baffle is your MDF ring.

Personally, if I were trying to cut a circle (if for some reason you want to stick with that idea), I'd use a reciprocating saw and a metal cutting blade (like I used for my line array, or just a jigsaw with a metal cutting blade. Draw your circle with a sharpie and cut away.
Just make sure you use a short enough blade that you aren't poking that metal behind it - that's the outer door skin of your car, and dents poking outward will really look weird..

[hobbes26]

The problem with using a jig or reciprocating saw is that there were wires in the way which were pretty hard to keep out of the way, as well as there being a track for the window to slide upon which was pretty close too...

Thanks for the help guys, but I ended up using the Dremel with the reinforced fiberglass cutting disc... it worked pretty well, with lots of sparks and lots of debris flying out at me...but hey, it still worked...

Two more nights work and I should be done with this portion of the install!

[texcon]

I was going to suggest the same thing as Geo - just cut some "slits" in the sheet metal every few inches (or however often you like) and bend back the tabs created by making these slit cuts. OR, take your door panels off and go to a welder or body shop and pay them to cut the holes. I bet it would take them a matter of minutes with the cutting tools they have.