Not sure what tools you have available, but I've seen some pretty simple things such as a dremel or rotozip, to drilling holes and using tin snips.

 

I used a dremel, each door used up a whole cutting wheel though. I threw off mad sparks, and at one point one of the wheels cracked and threw off a shard. It probably wasn't the ideal tool for the job, but tin snips would be really slow i'd imagine.

 

Snips aren't that bad, but they leave a sharp edge if you're not very good with them, and some of that sheet metal on the doors is pretty thick. If you have access and know what they are I would recomend some double cuts.

 

I used IIRC a Dremel and jigsaw w/metal cutting blades...oh, and a small hammer..it came in handy and nicely rolled the edges where it was a little snug and jagged...of course this was in my Grand Voyager work van so finesse wasn't on the agenda


Jeremy

 

how about one of those heavy-duty scisors that cut sheet metal and fencing? I used it to cut all sorts of things, but never on the door metal itself. It should work in theory but you gotta muscle it down.

 

I use a jigsaw with metal cutting blades. Although on my old 72 camaro the door was 1/2 thick up by the dash were all the layers came together. had to borrow a freinds plasma cutter for that.

 

Jigsaws are the easiest solution, IF you can get it in there. Otherwise a zip tool works well. Tin snips are tough because they'll sometimes bend the metal up.

 

I love using my pneumatic cutoff tool... I have a dremel, but as far as cutting sheet metal, cutoff tool all the way!

 

Well, the only tools I currently have that could possible do the job are a hacksaw and a power drill. The dremmel tool is a special bit for the power drill, right?

If it was a small jig saw, I think I could use it.

Basically, the factory hole is not a circle, it's an oval and it's slightly angled going upward from left to right. After putting the baffle over the hole, their is some metal in the lower-left part of the hole. The speaker goes in 95% percent of the way before the basket hits that metal. I don't think it will take too much to make it big enough for the speaker.

What is a zip tool?

 

Tin snips, unless you care what your door metal looks like.

-aaron

 

http://www.rotozip.com/ - RotoZip
http://www.dremel.com/en-us/tools/tool-detail.htm?H=188091&G=66981&I=69673 -Dremel

http://www.matcotools.com/Catalog/toolcatalog.jsp?cattype=T&cat=2128&select=#
- What I use. part #IR429 (Reciprocating Saw)

 

Sounds like an excuse to buy a new toy!

How about a plasma cutter?

http://www.plasma-cutter.com/

Being more practical, I agree a jig or reciprocating saw would be easiest and most readily available. Make sure you get fine tooth blades though to maintain control and reduce the likelyhood of damaging the door metal.

GL!

 

I've cut some small areas around my door speaker hole with a hacksaw. It takes a little work but it's not too bad.

 

i had to cut some of my frame as well and used a dremel. worked like a charm.

 

Pneumatic nibbers, Sha-Zam!

Chad

 

If you absolutely HAVE to use only a power drill, you could outline the new shape w/a black magic marker and then drill the outline out...It might take a while depending on how large an area you need to cut out but by drilling holes and then 'connecting the dots' w/a saw or snips, you could do it....

Does that make sense?? But for $25-30 you could get a basic jigsaw or dremel....

Jeremy

 

Besides the hack saw, of the methods you guys have mentioned so far, what is the cheapest that gets a good result?

 

Whatever's cheaper betweet the jigsaw and dremel I'd say....though I will say this, to me it was a little easier using the jigsaw because it keeps you at a set height and stable. With the dremel, you have to have a steady hand and control everything more. I like the dremel more for 'fine tuning' cuts,etc...

I paid about $25 for my Black and Decker jigsaw from HD a few years ago and still works great...I've built 5 sealed and ported boxes, cut metal doors and it's done great....

Jeremy

 

since u don't have much metal to remove, can use a half-round file. shouldn't cost more than a few dollars.

 

I'd suggest buying a Dremel just to have one. They tend to come in handy quite often. Rotozip is the bigger brother and the more heavy duty of the two.

I used my Dremel with the cutting wheel on my old Ranger, making room for some old 6x9s to go in the doors, lol. The lack of deadening pretty much made bass unbearable, but it did better than the tiny 4" ones up in the dash, lol. Buy extra cutting wheels. You'll use quite a few and break a few more. Besides that, it really is quick and easy, cuts like butter. The sparks will entertain you while you cut.

I tried a scroll saw first, ended up breaking the only, and quite old blade I could find. That worked well prior to breakage. The Dremel was option two, and it actually worked out a lot better than expected. I wonder if you could buy a thin carbide wheel for it...

 

Cheapest way? Get a nibbler.

http://en.wikipedia.org/wiki/Nibbler
http://www.directron.com/nibbletool.html