Re: cutting holes for factory AC vents
 

I used a milwaukee 1/2" drill with a handle that screws into the side co five better control. It didnt walk around because the drill bit keeps it centered. Drill the pilot hole first without the saw on the mandrel to avoid it grabbing when you drill through. I considered using my greenlee knockout set but the mandrel wasnt deep enough. I have a lot of cool tools that serve double duty being an electrician!
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Re: cutting holes for factory AC vents
 

LOL!!! Thanks....
I would have been scared too using a sawzall. The HF tool for $18 did the job...
I took my time and did the final fir with a die grinder and hand files.

Yes, it worked fine....BTW....that Lemans looks cool...
I love it! Down the road I'd like to find a 64 Lemans vert and drop an LSx with 6 speed. Clean up the body with all trim shaved off. Lower it and ride on ride tech suspension.
Lastly, what's that funny white stuff all over the ground? Do you drive your vert around in that? ;)

I'm sure it was like a 3 1/2" saw. That had to be tough. Have fun in Paris. I'll be there in September visiting the Louvre. Watching a video series by The Great Courses to familiarize myself. So much to see....impossible to do in one trip...:metal::metal::metal:

Re: cutting holes for factory AC vents
 

I'm pretty sure it is a 3-1/2 incher. I'm headed home tomorrow. If I'm not comatose when I get home I'll check the size.

I did the Louvre and Orsay today. No way could you see it all in a week. Look in to a Paris Museum Pass. I got a two day job for around 40 Euros. Also look into getting a navigo pass for the metro and RER. You don't want to drive here and the rails are pretty reliable.

Its looking like I'll be back in September too. I'm not a big city guy and this is a big city.

One or two more of us here in September and we'll have to plan a truck meet.

Re: cutting holes for factory AC vents
 

OMG...Louvre and Orsay in 1 day...Did you sprint through? LOL...
Yeah, we are gonna ride there from London on the Chunnel and spend 1-2 days just at the Louvre...My wife paints watercolors and chinese brush paintings, so she'll be in heaven...

Can you imagine our trucks in Paris? That would be a gas...

Re: cutting holes for factory AC vents
 

If you still have it saved would you wanna email a copy to me? I need to do the same thing here shortly.

Re: cutting holes for factory AC vents
 

If you still have the pdf template I would like to have it also since I will be adding air to my cab in about a month.

Re: cutting holes for factory AC vents
 

Guys, PM me your email address and I'll send it....

Re: cutting holes for factory AC vents
 

You can email me as well. daburb(at)gmail.com

Re: cutting holes for factory AC vents
 

PM sent

Re: cutting holes for factory AC vents
 

yall friggen rock DA-BURB, thanks for the photos with measurements!!

Re: cutting holes for factory AC vents
 

Mark the cut out using the template with the Old Aire kit, drill around the perimeter with a 1/2" drill bit.

Attachment 1492513

Use nibbling tool to remove remaining metal right up to the mark and finish smoothing with a file.

Attachment 1492514

Attachment 1492515

Attachment 1492516

Re: cutting holes for factory AC vents
 

What holds the top screw on the vent?

Re: cutting holes for factory AC vents
 

it is a sheetmetal J-clip very similar to the ones under your dash cluster.

Re: cutting holes for factory AC vents
 

I bought a A/C dash from someone here on the forum just the two ends, then I put clear tape over the holes and around dash to ends and cluster cutout and layered fiberglass over the holes, after it cured I marked the center of the hole, put the fiberglass template on my non A/C dash marked the center hole and area hole saw would not cut got a hole saw think 3-1/2" cut the hole then just used my Dremel to cut the small amount left to look like the factory, went pretty fast.

Re: cutting holes for factory AC vents
 

I have the two outer pieces of sheet metal that have the holes for the ducts I cut out of an a/c dash, if anyone wants them, I wont be needing them anymore. free, just pay the postage....
Let me know.
Ben
:metal:

Re: cutting holes for factory AC vents
 

Ben, I'm interested. Sending PM....

Re: cutting holes for factory AC vents
 

Does anyone have a template they could send me? Looking to use factory vents with the vintage air kit I am installing.

Re: cutting holes for factory AC vents
 

I should, I'll check when I get home.

Re: cutting holes for factory AC vents
 

That would be great! Hoping to wrap up my install by the end of the week and know I would regret cutting holes for the vintage air vents.

Re: cutting holes for factory AC vents
 

I have some that I cut out of an A/C truck, not so sure when I can get them in the mail

Re: cutting holes for factory AC vents
 

Pm'd you, I can hang the vent hoses under the dash until you have time.

Re: cutting holes for factory AC vents
 

Anyone have a copy of the template that was floating around in this thread? Thanks!

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.

Re: cutting holes for factory AC vents
 

I have dash cutouts left right and center, free to borrow.
I also have cab light cutouts for the light and switch.
$75 deposit, you pay shipping both ways, fits in small flat rate box.
Send me a private message for my phone number, then text me your name and forum name, keep me updated, i don't want to loose them.

Re: cutting holes for factory AC vents
 

Does anyone still have the template they could send me for the stock openings? Just ordered the vintage air kit but going with stock vents.