best DIY method for cutting side skin?

[twobone]

My new engine mounts raised my motor up a few mm. Now my headers press on the side skin where they exit the body. I assume the vibration and heat transfer are probably not a good thing.

 

Are there any hand tool DIY methods where I could cut off a bit of the ali side skin? Cutting wheel?

[yellowss7]

I used tin snips and a dremel with a sanding disc to smooth the edges. Use painters tape over the area to mark and cut.

 

Tom

[bsimon]

http://www.harborfreight.com/16-gauge-air-nibbler-96661.html

 

Best 30 clams I ever spent. Once you have one, you'll find more and more uses for it.

[Birkin42]

You can pick up a nibbler pretty cheap locally at Princess Auto.

I have one that you are welcome to borrow as well.

You'll need an air compressor to run the tool.

 

Jack

[MHKflyer52]

Use a drum sander that you can get at most good hardware stores. Here is a link to one such tool. http://www.harborfreight.com/catalogsearch/result?q=drum+sander

[twobone]

Was hoping to trim it with the headers in place to avoid rusty exhaust stud removal. Perhaps careful use of a dremel cutting wheel will work

[pi7ot]

I recently converted to Weber Twin DCOE 45.

I used a dremel with a flex extension to cut the fore and aft curves and a cutting wheel on an angle grinder to cut the horizontal lines.

Did not turn out too badly as I was conservative with the template. I Increased clearance with a tulip cutting head on a 3/8" drive drill followed by a dremel sanding drum.

Nothing quite like cutting a hole in a $400 bonnet.:cooldude:

 

m

[twobone]

I ended up using a dremel metal cutting wheel and a flexible extension. It was tricky as I was cutting around the headers while they were in place.

[pi7ot]

I ended up using a dremel metal cutting wheel and a flexible extension. It was tricky as I was cutting around the headers while they were in place.

 

I took my bonnet to a body shop and asked them to cut the hole.

They quoted "At least 250$".

I went home and thought about it, priced a new Bonnet(with the hole), and thought: 250 for cutting a hole??... Nahh!

 

m