Cutting A/C Vent Holes in Dash

[coop34]

Anyone have advice on how to cut out the holes in the dash for the A/C diverter balls for a non a/c dash? (Cutting only once is kind of important here)

[magwakeenercew2jh]

Hole saw. 2 1/2" for Vintage Air.

[gearys 5600]

My 69 was a non a/c truck, I put vintage air in the truck, but did not like the cheesy vintage air vents that came with my gen2 kit. I went to a salvage and found a 72 that had factory air, Traced the factory holes with a piece of paper and pen, taped them to my freshly painted dash and very carefully cut them out with a mini air saw.

Im pretty sure you can see a pic of them in my build thread.

[coop34]

magwa - did you use factory vent balls or vintage? Did you cut into the slanted part of the dash at all?

geary - what was cheesey about the vintage vents? I'm starting to think that that would be the easier route, although I already have the factory vents to install.

[gearys 5600]

I just didnt like them.They look and feel cheap. Now several of the aftermarket a/c manufacturers including vintage, make nice vents that you can buy, they are usually pricey.

[magwakeenercew2jh]

Originally Posted by coop34

magwa - did you use factory vent balls or vintage? Did you cut into the slanted part of the dash at all?

geary - what was cheesey about the vintage vents? I'm starting to think that that would be the easier route, although I already have the factory vents to install.

Well, last time I installed Vintage Air, I used factory vents. But I sort of like the VA vents. Different strokes, I guess. I think the VA vents, while not stockers or "correct", are less obtrusive looking and are a really easy install. No screws, etc. I've seen many broken
vent mounts at the screw holes on originals. As for the VA, the fit is just a hole. And then and come in from the back of the dash with the threaded "collar" to pick up the threads on the vent that you push thru from the front.

I used the VA template that's in the kit for placement at first. Then, I decided to look and feel around the back for the spot that was the most flat but had the most clearance. Basically, it was logical. And, even for me, a no-brainer.

However, I DID learn from the last time I made this cut in a non-air dash to take it easy with the hole saw...use a sharp one, a good drill bit. And, I opted for higher drill speed and lower pressure on the drill. Last time I did this, the hole saw
jumped out of the groove it was cutting and left a little gouge in the dash I had to look at for a while.

This time...slower and smart(er).

[72farmer]

I am installing a Oldair unit in my non air truck right now and it came with smaller than factory ball vents.I had to use a 2 1/4" holesaw and it worked out well after i called Oldair to find out how to secure them.I like this unit but the instructions are not in depth enough.

[mrein3]

I did this in the last year. I used a hole saw for the diverter balls. I'd have to confirm this but I believe I used a 3" saw. The center vent I cut with a dremmel tool.

[stevenfromtexas]

will the center vent fit in the ash trash opening???

[magwakeenercew2jh]

Originally Posted by stevenfromtexas

will the center vent fit in the ash trash opening???

Steven,

The ash trash is only for trash from ashes.

I guess you can make *anything* fit *anything*. But I'd venture that you're better off cutting the center vent hole where it belongs.....

Then again, if it's about custom, there are some very talented metal magicians reading this that would likely say different...

I use Vintage Air vents in a non-air cab. Never failed,,,,when I went slowly and used the correct tool for the job.

.

[Andy4639]

I cut the factory vents in mine. I used hole saw and snips and small grinder.

[stevenfromtexas]

wow!!! you inside looks very nice and clean!!

thank you for the reply.
i don't smoke and can't imagine anybody smoking in these pickups or any car/truck for that matter

thank you again for the pictures. i was curious of the placement of the "ball vents"

Originally Posted by magwakeenercew2jh

Steven,

The ash trash is only for trash from ashes.

I guess you can make *anything* fit *anything*. But I'd venture that you're better off cutting the center vent hole where it belongs.....

Then again, if it's about custom, there are some very talented metal magicians reading this that would likely say different...

I use Vintage Air vents in a non-air cab. Never failed,,,,when I went slowly and used the correct tool for the job.

.

[magwakeenercew2jh]

Originally Posted by stevenfromtexas

i don't smoke and can't imagine anybody smoking in these pickups or any car/truck for that matter

Thanks.

I don't smoke either. And no one smokes in my truck (or my car).

But, like I told the guy in the office next to me some years ago, after I followed him home, each of us driving our own car (he just bought a new Jag):

"Jim, America's a great place. A place where a guy that has the dough can buy a fancy car,
and no one can stop him from f*#king it up by smoking in it the first two minutes off of the showroom floor".

I meant it. His car, his money, his lungs.

Dremel, grinder, drill, and hole saw. Not in that order. No coffee. No beer....You'll be good.

[stevenfromtexas]

Originally Posted by magwakeenercew2jh

Thanks.

I don't smoke either. And no one smokes in my truck (or my car).

But, like I told the guy in the office next to me some years ago, after I followed him home, each of us driving our own car (he just bought a new Jag):

"Jim, America's a great place. A place where a guy that has the dough can buy a fancy car,
and no one can stop him from f*#king it up by smoking in it the first two minutes off of the showroom floor".

I meant it. His car, his money, his lungs.

Dremel, grinder, drill, and hole saw. Not in that order. No coffee. No beer....You'll be good.

thank you brother!!
i was thinking dremel also.
this will be the first add-on once i get my little guy going.

is that your stereo, with the screen?

[magwakeenercew2jh]

Originally Posted by stevenfromtexas

thank you brother!!

is that your stereo, with the screen?

Yeah.

Silly overkill: GPS, Sat Radio, DVD, and 10GB music loads. I usually know where I am, and prefer to listen to the motor over music. But my pal gave me this nice set up out of a car I sold him.
All I had to do is make the box and put some of the extra "kicker" carpet on it, buy a couple of speakers, and install the damn thing. I had nothing else to do when he dropped it off, so I went to town.

Nice spring day, windows open? Beats listening to canned music. Rather hear the rumble. But, what the heck? Every once and a while. Although, I dumped the $at radio subscription.....

[stevenfromtexas]

haha

NICE!!!

[Zeroman]

Yes, 3" is the size hole saw to use with a 12" long pilot rod.

I had old left and right vent bezels laying around so I ground off the portion that fits into the hole in the dash. Then I placed the bezels on the dash and traced the outline onto the dash. That gave me a place to start to center the hole.

Once I was happy with the center it was a matter of drilling the pilot hole and getting after it.

It is not easy as the hole saw will bite the inner portion of the hole first. It takes patience and strength to keep the hole saw straight.

I did chew up the left hole a little bit, and my body guy had to fill some metal back in but I very happy with the result.

Also, I did not notch the top of the hole as the originals have, and I just drilled a small hole for the bezel mounting screw.

[randy500]

Originally Posted by Zeroman

Yes, 3" is the size hole saw to use with a 12" long pilot rod.

I had old left and right vent bezels laying around so I ground off the portion that fits into the hole in the dash. Then I placed the bezels on the dash and traced the outline onto the dash. That gave me a place to start to center the hole.

Once I was happy with the center it was a matter of drilling the pilot hole and getting after it.

It is not easy as the hole saw will bite the inner portion of the hole first. It takes patience and strength to keep the hole saw straight.

I did chew up the left hole a little bit, and my body guy had to fill some metal back in but I very happy with the result.

Also, I did not notch the top of the hole as the originals have, and I just drilled a small hole for the bezel mounting screw.

Great info there, I'm gonna cut mine the same way.
What color is that truck? I like it.

[Zeroman]

Don't want to hijack the thread, but it is PPG Custom Kindig It Cool Clay, two tone with Toyota Arctic White top.

[jjzepplin]

I used stock vents too. I traced a real a/c truck dash and went to town. It was hard but the end result was nice. Dremel for the center.

[72 tigger]

Used a 3" hole saw also- went slow- turned out nice

[Tdrcreyn4]

I made a template from an AC truck then traced to my dash and used a reciprocating body saw. Done in 5 minutes and very easy to control.