How to cut dashboard?

[matthewmiller01]

What is the best tool to use to cleanly cut the simulated wood panels on the dash? Jigsaw? Rotozip? Cutoff wheel? Dull kitchen knife? Judo chop?

Seriously... What is the best tool to use? I know to use tape to minimize splintering.

 

[Nehalennia]

Laser. But I'm sure you don't have one of those. Remove from dash first. Tape the crap out of the area. Use a new blade for plastics. Keep the speed high and slower forward motion.

 

[matthewmiller01]

Laser. But I'm sure you don't have one of those. Remove from dash first. Tape the crap out of the area. Use a new blade for plastics. Keep the speed high and slower forward motion.

With what, a jigsaw?

 

[kaz911]

I used a Dremel with a plastic "cutting" thing - it takes time but works - but it took a couple of cutting blades - and some burn marks from melted plastic spray. On the fibreglass I used a jigsaw - but used the sanding wheels on Dremel to clean them up - the sanding wheels eats through the fibreglass like knife in butter.

But remember to measure any cut out templates before you use them. I had TWO different suppliers giving out cut out templates that was not correct measurement for their product...

 

[Gunn]

With what, a jigsaw?

You mention cutting simulated wood panels, but not for what. Are you cutting a round hole (drill bit) or rectangle (saw)?

 

[my DOG HOUSE]

I used a drill bit on the corners, the smallest tooth metal jigsaw blade I could find and lots of tape.

 

[matthewmiller01]

This is to enlarge the current mounting hole where my System View is to make it larger to accept my Vessel View. So it will be enlarging a rounded corner rectangle. Thanks!

 

[magstang1]

The roto zip cuts easily and cleanly, but it's a free hand cut. If you have room for a bit of variance, that's the way I would go.

 

[jerryd5515]

I used a roto zip to cut out opening for new c125 MFD in my simulated wood dash panel. Also enlarged opening in dash and had to take it slow or bit would overheat. Be prepared...noisy and dusty, but worked great.

 

[rcknecht]

$20 At Harbor Frieght, works great!

 

[JimFromMD]

I used a roto zip to cut out opening for new c125 MFD in my simulated wood dash panel. Also enlarged opening in dash and had to take it slow or bit would overheat. Be prepared...noisy and dusty, but worked great.

I have used a roto zip bit in my dremmel tool. Get a couple bits because as they cut throug the plastic they get hot and then dull down.

+1 on lots of dust. If you have a helper nearby... have them hold a vaccuum close to the bit as its cutting to suck the dust right up. Also... do yourself a favor and wear a long sleeve shirt and pants. My arms and lower legs (shorts and a tshirt) were itching for the better part of a day until a few showers and towel offs pulled all the fiber dust out of my skin.

One last thought... trace your paper cutout template from the mfgr onto a thin piece of wood.... then rotozip out the inside of the template.... then secure your new wood template to the dash and use that as a guide for the solid (not grooved) portion of the rotozip bit. You can bump that solid part up againt the template wood and not cut it, while the grooved portion of the rotozip bit is doing the cutting in your dash. You'll have the perfect cut afterward.

 

[matthewmiller01]

Thanks all. I hope to be making this upgrade soon, but work will likely get in the way for the next two weeks.

 

[CSR_Admin]

http://www.youtube.com/watch?v=U_xi6FzKygY

 

[matthewmiller01]

Thanks, Jim. Do you have one for the simulated woods rain panels?

 

[Danny Troy]

I'll second (or third) the Rotozip. If you have a Harbor Freight store near you, they have a cutout tool, similar to the Rotozip, and a lot cheaper. It does the job for me. I bought a collet set for the Rotozip at Home Depot, so I can use the more heavy duty Rotozip cutting bits in the HF tool. I recently used it to cut 4 holes to add receptacles in my 280. I finished it up with a Dremel with the sanding drum, to sand down the rough edges.

Yes, use a vacuum and probably a face mask, since it puts a lot of dust in the air.

 

[Nehalennia]

With what, a jigsaw?

Yes I'm sorry a jigsaw with the proper fiberglass/plastic blade.
http://www.zorotools.com/g/00144032/k-G5026637?utm_source=google_shopping&utm_medium=cpc&utm_campaign=Google_Shopping_Feed&kw={keyword}&gclid=CP-29tDWorcCFaF7Qgod10UAdA

 

[matthewmiller01]

Yes, use a vacuum and probably a face mask, since it puts a lot of dust in the air.

So the simulated wood panels (inserts) create a lot of dust? I am not cutting fiberglass (unless they are made of fiberglass too - like the actual dash).

 

[Danny Troy]

It will probably kick up some dust, even if it isn't fiberglass, so at least use a vacuum. I use a technique where I hold the vacuum and the cut-out tool with one hand, while holding with a good grip with the other hand. Of course, if you have a second person there they can direct the vacuum.