got photos should anyone be ever so slightly interested..

marked out with scriber then thought 2 minutes with the electric nibbler should see it done - wrong!!!! the nibbler needs 8 mm hole which is too big.

so resorted to hand nibbler, and after a trial on some scrap it did the job with minimal distortion.

Three 5.5 mm holes drilled close together then opened out to a slot to start the nibbler off followed by two passes as the nibbler cuts just under 3 mm.

Then used a 6 mm drill bit and a file to ensure the gap is even and it's sorted!!

This is the aluminium sheet with finished slot and curved to fit scuttle - note the slot curves at one end.

slot cut

and fitted - taken in the dark so camera did not focus too well. once painted black, should look dead smart.

surround fitted

[Edited on 12/9/07 by 02GF74]

Another nifty way of doing it is with a dremel type tool with a cutting disc in it....

Or a 6mm carbide bur thing - about £5 on ebay and will cut the slot before you've even started the drill!

Pat...

quote:

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Originally posted by Avoneer
Or a 6mm carbide bur thing - about £5 on ebay and will cut the slot before you've even started the drill!

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nowthat you mention it, I did watch rotazip demo that works in the same way; not sure if the result would have been as neat - slot is 340 mm long and is cuervet at one end - I would have to have made a guide for the bit as doing it free hand would expect the tool to wander.

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Phil.J - 11/9/07 at 11:48 AM

A 6mm slot drill mounted into a cheapo router will do the job very neatly, and you can run it along a straight-edge

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