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**Jason Banks** · 02-01-2020, 10:39 PM

I recently did this and used a template like in post 38 above. It wasn't that one exactly but very similar, where it had the shape and some reference dimensions, so I could adjust the size it printed.

I cut out the opening and taped it to the dash. Then I traced the opening with a pencil on the dash.

I used a cutting wheel and cut out a chunk of metal and then used a nibbler to cut out much of the rest and then fine tuned the shape of the hole with an air file(the belt sander kind). The air file was amazing to get the final shape. It would be hard to tell the holes were not factory cut.

02-01-2020, 10:39 PM	#48
Jason Banks Senior Member Join Date: Dec 1999 Location: TX Posts: 1,529	Re: cutting holes for factory AC vents I recently did this and used a template like in post 38 above. It wasn't that one exactly but very similar, where it had the shape and some reference dimensions, so I could adjust the size it printed. I cut out the opening and taped it to the dash. Then I traced the opening with a pencil on the dash. I used a cutting wheel and cut out a chunk of metal and then used a nibbler to cut out much of the rest and then fine tuned the shape of the hole with an air file(the belt sander kind). The air file was amazing to get the final shape. It would be hard to tell the holes were not factory cut.