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CC Advertisers
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08-05-2003, 09:43 AM
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CC Member
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Join Date: Apr 2000
Location: Leesburg,,
VA
Cobra Make, Engine: ERA Cobra #273, 427 S/O, ERA GT-40 #2057, Excalibur Cobra.
Posts: 1,011
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Not Ranked
Big Hole Punch
NO - -I'M NOT LOOKING FOR A PROCTOLOGIST WITH AN ATTITUDE.
I WANT TO REPLACE THE "LESS THAN ADEQUATE" S.W. GAUGES IN MY ERA COBRA WITH AUTOMETER - SMITH REPLICAS.
I'M LOOKING FOR A HOLE PUNCH OR CHASSIS PUNCH BIG ENOUGH TO ACCURATELY PUNCH OUT THE HOLES IN THE INSTRUMENT PANEL TO THE PROPER SIZE.
TRIED EVERWHERE - - FIRST TIME EVER I HAVN'T FOUND WHAT I WAS LOOKING FOR AT McMASTER-CARR.
ANY SUGGESTIONS WOULD BE GREATLY APPRECIATED. THANKS, AND Y'ALL HAVE A REALLY GREAT DAY.
BLACKJACK
__________________
It's impossible to make anything FOOLPROOF - - Because FOOLS are so ingenious.
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08-05-2003, 10:16 AM
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CC Member
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Join Date: Mar 2002
Location: so cal,
Cal
Cobra Make, Engine: I used to fix them for a living
Posts: 2,563
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Not Ranked
Careful use of hole-saw
__________________
In a fit of 16 year old genius, I looked down through the carb while cranking it to see if fuel was flowing, and it was. Flowing straight up in a vapor cloud, around my head, on fire.
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08-05-2003, 10:56 AM
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Senior Club Cobra Member
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Join Date: Dec 2001
Location: Glendale,
AZ.
Cobra Make, Engine: Cobray-C3, The 60's body lines on todays chassis technology
Posts: 2,302
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Not Ranked
I think you are looking for a GREENLEE punch used most commonly by the electrical trade for adding knockouts in panels. You can not use a hole saw as the center is already gone from smaller gauge if I guess right. Go to any electrical supply house or maybe Ace hardware (they stock them here in Phx. ) but they are a little spendy.
I have used a good carbide bur on a die grinder with good results. I tape the area with 2 or 3 layers of duct tape just incase it skids on me. Then hang vac. hose near work and brace hand against work to control better. Go slow and good luck!
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08-05-2003, 11:04 AM
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CC Member
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Join Date: Jul 2001
Location: Southwest,
WI
Cobra Make, Engine: Shell Valley, Mopar thingy (small block of course)
Posts: 2,215
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Not Ranked
You could always clamp a thin plywood behind to center the hole saw.
__________________
Brent Dolphin
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08-05-2003, 11:07 AM
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Club Cobra Member
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Join Date: Feb 2003
Location: Sterling,
IL
Cobra Make, Engine: SPF #1507 427 Dart Block Windsor
Posts: 1,192
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Not Ranked
You can use a hole saw if you clamp a piece of wood to the dashboard.
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08-05-2003, 11:09 AM
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Club Cobra Member
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Join Date: Feb 2003
Location: Sterling,
IL
Cobra Make, Engine: SPF #1507 427 Dart Block Windsor
Posts: 1,192
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Not Ranked
Hah! Looks like ya beat me to it, Brent!
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08-05-2003, 11:12 AM
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CC Member
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Join Date: Feb 2001
Location: Patchogue. NY,
NY
Cobra Make, Engine: Midstates 351W tremec
Posts: 60
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Not Ranked
Blackjack,
What I would suggest is get a couple of scrap sheets of plywood. Trace around the existing hole of the gauge you wish to make bigger. Drill a pilot hole the same diameter as the pilot drill for a hole saw for the new size. Then realign the scribed hole to the dash hole.
Then sandwich the dash between the scribed hole and the other scrap piece of ply using clamps. Then carefully use the pilot hole to drill completely through the dash. The wood will support the dash and give you a real clean cut.....
Steve
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08-05-2003, 11:43 AM
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CC Member
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Join Date: Dec 2000
Location: Broken Arrow. OK ( South Tulsa), USA,
OK
Cobra Make, Engine: 66 COBRA FE 427 /4SP. (HCS Coupe w/ 408 Stroker and TKO 600 -sold)
Posts: 5,595
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Not Ranked
Blackjack,
Are you going from 2 1/8 " to 2 5/8" gauges? If so I watched a friend of mine ream his out with his die grinder. Same method as mentioned above. Took him about 15 minutes to do all five gauges. I held the vacuum.
Clois
__________________
Sunshine, Asphalt and no stop signs...Perfect
"Let's roll"
"Be part of Something Good
......Leave Something Good Behind!"
from CD "Long Road Out of Eden"
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08-05-2003, 12:38 PM
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CC Member
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Join Date: Jun 2000
Location: Warrenton,
VA
Cobra Make, Engine: FFR2229K, Vortech-blown 306 (446rwhp, 442 rwtq)
Posts: 236
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Not Ranked
Jack - is eyesight the second or third thing to go?..... 
I have an adjustable holesaw that I used to cut out the gauge holes in both FFR's. It's meant for wood, but it cuts a PERFECT hole in sheet aluminum. It's best used in a drill press though since it has only one cutter and must be held perfectly perpendicular to the workpiece. I can bring it to the VI if you want it.
__________________
Wade Chamberlain
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08-06-2003, 06:16 AM
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Senior Club Cobra Member
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Join Date: Feb 1999
Location: New Britain, CT,
Posts: 1,416
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Not Ranked
Jack,
Since our dash is fiberglass and the small gages are the same size (unless you've got some weird ones), I would use a sanding drum or roll and enlarge the holes by hand drill or die grinder. It's only the difference between 3 5/8" and 3 7/8" diameter for the speedo and tach.
Sanding drums
I've never used one of these, but it would probably work.
Flap sanding wheel
__________________
Bob Putnam
- E.R.A.-
Please address parts inquiries to eraparts@sbcglobal.net
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08-06-2003, 07:40 AM
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CC Member
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Join Date: Apr 2000
Location: Leesburg,,
VA
Cobra Make, Engine: ERA Cobra #273, 427 S/O, ERA GT-40 #2057, Excalibur Cobra.
Posts: 1,011
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Not Ranked
BOB - - -
THANKS VERY MUCH. I WASN'T AWARE THAT THE INSTRUMENT PANEL WAS FIBERGLASS.
BY THE WAY - - - ERA 273 IS RUNNING GREAT. MOST OF THE MINOR BUGS HAVE BEEN WORKED OUT AND IT'S REALLY A ROCKET.
DYNO SHEET READS 525 HP. MORE THAN I NEED - - ALMOST AS MUCH AS I WANT.
YOU GUYS MAKE THE GREATEST CARS - - - THANKS.
I CAN'T WAIT TO GET INTO MY PERMANENT GARAGE AND START BUILDING A 289 "STREET" CAR.
Y'ALL HAVE A REALLY GREAT DAY,
BLACKJACK
__________________
It's impossible to make anything FOOLPROOF - - Because FOOLS are so ingenious.
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08-06-2003, 11:46 AM
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Senior Club Cobra Member
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Join Date: Jun 2001
Location: North Metro Atlanta,
GA
Cobra Make, Engine: 2 dr roadster, V-8, 4 spd.
Posts: 2,780
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Not Ranked
BLACKJACK,
Saw your other post on cleaning wrenches and somone recommended some gun cleaner. I am sure that the gun shop, while you are there getting the cleaner, has something that could enlargen those holes quite easily  |
08-06-2003, 02:00 PM
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CC Member
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Join Date: Dec 2002
Location: Kennett Square, PA, USA,
Posts: 201
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Not Ranked
Blackjack,
The hole saw will work. Just stack them . The new size on the mandrel first, followed by the old size. The inner one, old size will act as a big pilot bit and align the new one.
We use this method when one of the guys drills the wrong hole in a pipe for a mechanical tee.
Fibergless should be a piece of cake, but go slowly.
Bud
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08-06-2003, 04:05 PM
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Senior Club Cobra Member
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Join Date: Feb 1999
Location: New Britain, CT,
Posts: 1,416
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Not Ranked
Jack,
Use a razor blade to pre-cut through the vinyl covering. The vinyl is glued to the 'glass, but if it comes loose during the enlarging process, you're in big trouble. 
__________________
Bob Putnam
- E.R.A.-
Please address parts inquiries to eraparts@sbcglobal.net
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