boss351 Posted July 20, 2013 Share Posted July 20, 2013 Can I get some tips on cutting a hole in the bonnet, it is to place some mesh in (like a CSR) where my new ITB's are. I have an SV so the filter is almost enclosed in the bonnet (about 3-5mm out at the front), I don't mind the filter being crushed a little, there is a lot of air space to the top of the TB. What is the best tool/technique to not make a mess of the paint and look like it was done properly? Thanks. Adam Link to comment Share on other sites More sharing options...
boss351 Posted July 20, 2013 Author Share Posted July 20, 2013 Sorry, attached the blurry photo, this one is better! Link to comment Share on other sites More sharing options...
jlumba81 Posted July 20, 2013 Share Posted July 20, 2013 Tape around the area you are cutting so the paint doesn't chip and use an air saw. Use a drill to make a start hole. Could also use a jig saw. Link to comment Share on other sites More sharing options...
pi7ot Posted July 21, 2013 Share Posted July 21, 2013 Hope this helps. 1 http://img.photobucket.com/albums/v289/thegit/Se7en/BonnetMod4.jpg 2 http://img.photobucket.com/albums/v289/thegit/Se7en/BonnetMod6.jpg 3 http://img.photobucket.com/albums/v289/thegit/Se7en/bonnetMod7.jpg 4 http://img.photobucket.com/albums/v289/thegit/Se7en/BonnetMod8.jpg Then clean up the circumference of the hole. I used a Dremel with flexible adapter and cutting wheels for the initial cutting then used an angle grinder with a cutting wheel to completely cut through the aluminum. m Link to comment Share on other sites More sharing options...
boss351 Posted July 21, 2013 Author Share Posted July 21, 2013 Thanks, going to attempt this next week. Lots of masking tape. Some practice on a piece of aluminium that I have first. Link to comment Share on other sites More sharing options...
DeanG Posted July 21, 2013 Share Posted July 21, 2013 Good luck. It scares me any time I have to make a hole. Measure, measure, measure. Link to comment Share on other sites More sharing options...
jlumba81 Posted July 21, 2013 Share Posted July 21, 2013 You can use a jar or coffee can to make a template for the curves on the sides. Put it on cardboard/paper then transfer to the hood. Link to comment Share on other sites More sharing options...
slomove Posted July 21, 2013 Share Posted July 21, 2013 Good luck. It scares me any time I have to make a hole. Measure, measure, measure. Holes are no problem. If they are in the wrong place just make them bigger :jester: Link to comment Share on other sites More sharing options...
Klasik-69 Posted July 21, 2013 Share Posted July 21, 2013 I used an air nibbler which cuts a 3/8" notch. It doesn't distort the metal. However, Eastwood sells a hand operated metal shear that is supposed to be a lot better and doesn't distort the metal either. I believe the hand shear is also a lot more accurate since you go at your pace rather than the tool. Having said that, it looks like you can avoid cutting the bonnet by taking the ITG air cleaner and giving it a little rubber mallet revision. If you can avoid cutting the bonnet, do it. When it rains, you won't have to worry about the foam element getting soaked. I wish I could have avoided it with mine but mine is a S3 chassis and there just isn't the room for the ITB and air filter. Link to comment Share on other sites More sharing options...
boss351 Posted July 21, 2013 Author Share Posted July 21, 2013 Having said that, it looks like you can avoid cutting the bonnet by taking the ITG air cleaner and giving it a little rubber mallet revision. If you can avoid cutting the bonnet, do it. When it rains, you won't have to worry about the foam element getting soaked. I wish I could have avoided it with mine but mine is a S3 chassis and there just isn't the room for the ITB and air filter. Even with the hole I intend to give the filter the rubber mallet treatment and put in a mesh grill. The hole is more for getting outside air in to the intake rather than under the bonnet air. Got the nibbler (under $30 at Harbor Freight) and will take some practice cuts on a piece of aluminium sheet I have. Link to comment Share on other sites More sharing options...
MHKflyer52 Posted July 22, 2013 Share Posted July 22, 2013 I would use this tool as it is more controllable in my humble belief and it is not that expensive at Harbor Freight and is on sale now for $18.99. High Speed Metal Saw Central Pneumatic - Item#91753 Don't forget to get the blades for it and use the fine tooth bi-metal saw blades. You could also use a Jig saw if you have one already just use tape on the surface of the bonnet / Hood to keep the foot of either saw or nibbler from marring the paint and when you remove the tape make sure you peel it towards the cutout area so as to not lift the fresh cut edge of the existing paint as sometimes the existing paint will lift at the cut face. Hope this helps. :driving: Link to comment Share on other sites More sharing options...
boss351 Posted August 4, 2013 Author Share Posted August 4, 2013 We used an air saw and made clean cuts. Added the edging trim because it looked better: Link to comment Share on other sites More sharing options...
MHKflyer52 Posted August 4, 2013 Share Posted August 4, 2013 We used an air saw and made clean cuts. Added the edging trim because it looked better: Very nice job, and looks like it was factory. Link to comment Share on other sites More sharing options...
boss351 Posted August 5, 2013 Author Share Posted August 5, 2013 Very nice job, and looks like it was factory. Thanks, now mulling over doing a matching one on the exhaust side. Link to comment Share on other sites More sharing options...
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