Need help with a modification please!

[JustGotOne]

I'm wanting to modify the space where a 1" tweeter was mounted in my rear door panels to be able to mount a 3 1/2" full range speaker. My issue or lack there of (depending on how you look at it) is what do I use to make the cut? I have the template for the hole, (it's marked) I have a variable speed jigsaw, and I have hole saw bits as well but I don't want to make a rough cut.

My next thing would be figuring out a way to make a grill that would fit. I'm thinking if I can't purchase them, make my own. I've got to come up with a grill for the speakers in the dashboard. I originally got them to place one in the center of the day and decided to hook them up in the tweeter spots to see his they would sound.

Any suggestions would be appreciated. Thanks in advance!

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[Jeffdachef 5,000+ posts]

You cut it very carefully with a steak knife.

Jk @CSCStang ; made a cut like that, he can tell you what tool he used

 

[JustGotOne]

lol @ Jeffdachef, I've done that before! LMBO But thanks bro!

 

[hispls 5,000+ posts]

Nibbler tool works nicely for sheet metal or plastic panel trimming. Obviously power tools (dremel, hole saw, jigsaw) are quicker but they are not very forgiving.

 

[CSCStang]

lol @ Jeffdachef, I've done that before! LMBO But thanks bro!

With a spare block scrap of wood behind the cutout, I lined up the hole with the wood and used a hole saw on low speed so it wouldn't tear up the plastic. Worked perfect.

 

[JustGotOne]

Nibbler tool works nicely for sheet metal or plastic panel trimming. Obviously power tools (dremel, hole saw, jigsaw) are quicker but they are not very forgiving.

Found one on ebay for $16, I'll wait on it, shouldn't take too long to show up. In the mean time I'll figure out how I'm going to do the grill, I don't think I want to leave it exposed. If I can't find a premade grill to my liking will try my hand at making one myself. I did try something with some cheap 1/2 in plywood and grill cloth for the dash speakers but I didn't like the finished product. I have plenty of that material left to try some other options.

Thanks again for the suggestions. I'll be sure to post pics once I have them installed.

 

[JustGotOne]

With a spare block scrap of wood behind the cutout, I lined up the hole with the wood and used a hole saw on low speed so it wouldn't tear up the plastic. Worked perfect.

Definitely thought about the hole saw, tin snips would have worked too, but I think the cut would have been a bit jagged. Wanted to make sure the cut was as smooth as I could get it, because at least it will look ok until I can get the grills done.

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[JustGotOne]

Update: Here are some pics of the outcome - wound up having to use tin snips where the plastic was too thick for the nippers, and had to trim the vinyl and foam backing off the area I wanted cut because the nipper opening wasn't wide enough. I fashioned the grill out of a mesh folder holder I bought at Staples for $13. It was actually enough to do the grills for the dash speakers as well.

Comments or critiques are welcome. I'm no pro, but I'm trying, and I'm sure someone may have a better idea or different way to get it done.

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[keep_hope_alive Premium Member]

i use a dremel and plastic cutting disc to trim plastic. works like a charm.

 

[jeepguylv]

one of my favorite tools for cutting door panels and dash/interior parts is a cheap air body saw from harbor freight, I know it may not be ideal, but I have a steady hand and I like the versatility, kinda like a mini sawsall .

 

[JustGotOne]

one of my favorite tools for cutting door panels and dash/interior parts is a cheap air body saw from harbor freight, I know it may not be ideal, but I have a steady hand and I like the versatility, kinda like a mini sawsall .

I like that tool, I'm definitely going to purchase one I looked at an electric one for like $32, that would surely work for a number of projects.

Thanks again! //content.invisioncic.com/y282845/emoticons/cool.gif.3bcaf8f141236c00f8044d07150e34f7.gif

 

[JustGotOne]

i use a dremel and plastic cutting disc to trim plastic. works like a charm.

Didn't even think of a dremel, another tool I need to pick up just to have in the arsenal.

Thanks

 

[big scott]

one of my favorite tools for cutting door panels and dash/interior parts is a cheap air body saw from harbor freight, I know it may not be ideal, but I have a steady hand and I like the versatility, kinda like a mini sawsall .

how do you like that body saw ?

i need to get one and i like to get a corded one. as my compressor is to small to operate one.

one day ill get a good compressor lol...

 

[jeepguylv]

I like it a lot, my compressor keeps up most of the time, but when I was cutting my fenders to fit the larger tires I would have to cut a third of it, let it fill up then cut another third and so on, but other then that I would like to get an electric one to, that way when i'm working late I don't **** off the neighbors lol.

one thing that makes me mad is I had a nice dremal kit that cost me like $159 and I happen to pull out the box a couple years ago and opened it and about had a heart attack lol dremal and all attachments where gone, just the box, a couple cut off wheels, and the bracket for the adjustable hole saw thing to cut circles, still never found it .

 

[fasfocus00 5,000+ posts]

tape over the area you want to cut with painters tape. cut out a ring of 1/2" mdf. glue the mdf ring to the painters tape where you want the hole. than use a top bearing flush trim router bit.