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PostPosted: Sun Dec 30, 2012 10:12 pm 
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Joined: Tue Dec 04, 2012 4:04 pm
Posts: 70
Cutting Bonnet for Exhaust

1. Firstly make an accurate as possible template using cardboard etc

2. Place several layers of masking tape over the area you wish to cut out. Infact 4 layers is best. Then mark out using your template as a guide. I used a hole cutter to create nice curves. Marked the centre of the holesaw for accurate cutting.

3. Pilot drill using a drill smaller than the holesaws centre drill. This makes sure the hole cutter is dead centre. Then carefully cut out the larger holes using the hole cutter. The 4 layers of masking tape stop the holesaw chipping the gel coat

4. Using a grinder with 1mm cutting disc cut out the sections between the holes following your pencil lines closely.

5. Now use 80 grit sandpaper to round off sharp corners and generally clean up the cuts.

6. Trial fitting and tweaking.

7. Final fit, fits nicely (4th pipe is sloped more of an angle making the gap look bigger in the picture, but in real life its perfect)




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