Going to cut a hole in my narrow bodied Westfield to accomodate the R1 airbox.

Any tips?

Best way to cut it?

cover in masking tap and draw on what you want to cut out

i used a jigsaw (on a slow setting) to cut out the main body of the piece to be removed

then used dremel to remove off further grp to the line markings

[Edited on 11/7/09 by omega0684]

1mm cutting disc or a couple of drill holes then by hand with a hacksaw blade.
file to finish

I made a card template and then copied it across to the bonet.

measure more than twice and cut once.

Are you worried about HOW to cut the hole, or WHERE it should go?

If the question is 'Where?' then I'd cut out a cardboard template and hack that around (if you cut off too much, you can always glue a bit back on). When you've finished, stick it to your bonnet and cut.

Recently did similar for vents in my MK bonnet.
Cut out ideas in card to see that it looks OK.
Masking tape to cover the outline then detail lines onto the tape.
Drill holes just inside the line.
Join-the dots with Dremel side-cutting drill. Great care needed, but can be quite accurate.
Straighten up edges off with Dremel emery tube thingy.
Get a finer finish with fine sandpaper and wood blocks (flat & round)

shut you eyes,and hope.

hole saw and flap wheel

Cheers guys.

My plan was to.....

Fit air box and rest bonnet over.
Drill small holes from above, working outwards to just within required area.
Join holes with hand held hacksaw blade saw.
Finsh with emery block.

Sound ok?

Its quite tricky to work out the area required

emery block will take you forever!

Mount a laser from the roof/ceiling and line it up with a corner of the airbox then fit the bonnet mark the bonnet then do the same for the other corners, this will give you a starting point to work from and providing you dont move the car in between they should line up. Does that make any sense.

Makes sence. Will contact Dr Evil in the morning for a "giant lazur"

You can use one of these small pocket one.

Yeah, but where's the fun in that?

I think having a few beer prior to starting is not a good idea. Although if I keep going on my car much longer, I'm going to start drinking again.

I used masking tape to draw the shape i wanted. Then used Rotozip (dremel type thing) with new bit to make the cuts. Cut it freehand then cleaned the cut edges with emery tape. Very scary job at first but take your time and good result will be obtained. Cover yourself up with appropriate PPE - the dust gets everywhere and is very irritating.

Cheers guys.

Not done it yet due to a few reasons.

(1) Its a very rare Westfield narrow body bonnet
(2) I already have a hole where the twin 40's used to stick out... weakening the bonnet?
(3) cluck, cluck.. im a chicken

[Edited on 15/7/09 by Major Stare]