need help making holes in fenders for front cage - Defender Source
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  #1  
Old April 18th, 2010, 01:35 AM
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dmitry
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need help making holes in fenders for front cage

Purchase fenders, blank, no holes for lights nor for cage support pillars.
What is the best way to make holes?
Anybody has pre made shapes to help to do that? Any suggestions how to not bend it, while drilling and cutting?

------ Follow up post added April 18th, 2010 02:05 AM ------

found the link
//www.roverworld.com/rollbar_english2.htm
Anybody has template?
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  #2  
Old April 18th, 2010, 05:32 AM
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You don't have the old fender for measurements? I don't have template, but the basic approach is to cover the area with masking tape, then draw your opening onto the tape. Start drilling small holes and work up to a larger bit so that when you are done you have radiused corners for your opening. Then just connect the holes by cutting with a dremel tool or similar. Then just finish up with a fine file.
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  #3  
Old April 18th, 2010, 07:43 AM
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Like Jim says... make template.... mask the area, drill corners. maybe a3/8 drill.. I then use a 2" cutoff wheel and cut between and you are done.. take about 15min..

I think the front marker light hole on the 94 you can use a hole saw..
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Old April 18th, 2010, 11:30 AM
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Measure twice, cut once.
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Old April 18th, 2010, 01:43 PM
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The masking tape really helps.
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Old April 18th, 2010, 01:48 PM
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Quote:
Originally Posted by TDI Guy View Post

I think the front marker light hole on the 94 you can use a hole saw..
To expand on this a little bit.

Make sure its a fresh and true hole saw, and absolutely use a solid backing.
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Old April 18th, 2010, 11:49 PM
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You can always go with a dremmel cutting wheel and go slow.
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