During my duratec transplant I need to enlarge the outlet for the exhaust. How can I do to enlarge the hole where the exhaust exit with minimal damage to the paint work?

Thank you in advance!

I would use a jigsaw with a very fine cutting blade but first put masking type all over the area where you are cutting

I'd go with a flap wheel and patience, you should be able to touch the edges in, or use a trim.

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Originally posted by jacko
I would use a jigsaw with a very fine cutting blade but first put masking type all over the area where you are cutting

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You could try masking the area with tape, then gently cutting the outline with a craft knife. Carefully cut away up to your score line.

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Originally posted by deltron63

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Originally posted by jacko
I would use a jigsaw with a very fine cutting blade but first put masking type all over the area where you are cutting

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That's how i did mine

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I had a similar problem so I used a holesaw supported by plywood at rear. Worked for me.

Sheet metal nibbler. The type that leaves thousands of tiny sharp new moon shaped scraps that get in your fingers for weeks after. This ones a snip but there are 30 more from £16 upwards on ebay. Fein Sheet Metal Nibbler BLK 3.5, 10 Gauge (110V) | eBay


[Edited on 19/11/11 by Dusty]