[frankym]

When i actually find my spot to make the new hole, i need to do two things (assuming placement and size are good)

1. I need to preserve the cutout intact to use as a plug for the existing hole.

2. Minimize the splintering of paint along yhe edges of the hole.

Here is my plan. Put an accessory shop light in the trunk overnight to keep the paint fairly warm. Put wide painters tape over the painted surface to be cut. Mark the ellipse with a sharpie. Use a spiral saw to make the initial cut. Then use a fine blade on my bosch jigsaw. Then use low rpm to slowly cut out the hole.


I am considering not redoing the body and putting a static meatball to cover the hole. I might reaffix the hole insert by filling the small gap (after positioning the cutout plug) with something called q-bond which is amazing stuff. Its fine powder that fills the void then drop the glue and it hardens within 5 seconds like a rock.

I plan to mock and weld as soon as that rollbar comes in maybe tonight. Cutting the body is very last major step.