Cutting body panels

[othtim]

Hi there. I'm currently on a kick to lighten my Monte. A few days ago I took apart my passenger door, and attempted to cut out a bunch of the inner panel. I've been using an electric Sawzall - hasn't been working out. The sawzall is really jumpy, and doesn't do well cutting a corner. I'm nervous to use a plasma cutter, because I don't want to damage the outer door skins. I was hoping someone might have suggestions as to what tool would work better than the sawzall. Thanks for your time.

 

[beermonkey9417]

a dremil or a dual saw would work, or if ya have an air grinder, thatll werk too.

 

[MR442]

Go get a bi metal hole saw kit . Just couple diff sizes . Take time and think it out . But by cutting out circles the little metal left between will still keep strength to panel . I used to take them to every panel when I drag raced a pickup.

Dont take large areas out . Leave 1/2 web between or so. Or you will find things start to flex way easy .

All those holes add up weight wise

 

[othtim]

I tried a bi-metal hole saw kit. I couldn't keep the interior door panels stable. They would jump all over, and I broke two bits in the hole saw kit just from the door flexing all over the place. The door is ON the car btw.

 

[carmangary]

I rough it with a nibbler or angle grinder with a cutoff wheel then finish up with a dremmel tool and cutoff wheel and or flap sander on a angle grinder.

 

[Blake442]

I'm nervous to use a plasma cutter, because I don't want to damage the outer door skins.

Stop being a wuss and start cutting...