I need to cut a rather large hole in my roof (MK3 breadvan)

Only tools i have are a Grinder and a Jigsaw

Grinder is far far too easy to make a mistake and go where you dont want to, and the cutting discs are FAT

Jigsaw, I've never used on metal before.. Are they any good?

Obv, i need it to be accurate, a thin cut and easy enough to control. If i make one mistake in the wrong direction its game over

Any ideas on tools? That are cheap (or cheap to hire) that would do a better job than the above two?

Or even better, anyone got anything they could lend me for a day?

Edited 15 November, 201114 yr by B-shaw

Plasma cutter? Expensive.

Can you not get thinner discs? Take your time and don't cut away at the margin of the hole you need straight off the bat. Allowing you to get practice at cutting the area successfully. Also provides a bit of damage limitation. Do it in managable sections rather than trying to do one big long cut without stopping. Use a dremel for any fiddly bits in the corners etc? Then just grind back/cut the metal to the required size etc? Will be time consuming but i think if you get some good quality, thin cutting discs and give yourself plenty of time you will be able to do a satisfactory job.

Also make sure that you have plenty of room to move around. The times you make the biggest mistake cutting (any power tool use really) is when you are trying to do it at an awkward angle and you don't have full control of the tool in hand.

Pretty daunting and i don't envy you

Edited 15 November, 201114 yr by demolover

Petrol disk cutter ftw!

Nahh just get some proper cutting disks, not stone grinders

Let me do it, I'm fucking ace with a grinder

Get plasma disks. There silly thin.

And don't set everything on fire.

I have some discs that are 8mm thick. Go through 10mm steel like butter, so will be fine on a poncy roof. But as mentioned above, its going to need some strength!

Cutting discs i have are massive thick, I've never looked into others though

I was thinking to cut too small then grind the rest back, but can end up messy.

And Ben, I'm not feeling rupping out the headlining on the coupe to look haha.

I've got some ideas of bracing... but i honestly cant see how its structural? the roof flexes to fuck... just like a bonnet does. If anything, it will be stronger with the frame of the sunroof in. Especially as it goes so close to the edge. Its not asif its a little hole in the middle, it removes about 75% of the roof panel.

cut it with a grinder and thin disk, (stainless steel or steel) But DO NOT grind it back with the grinder, if you catch it wrong the roof will warp, it happened to my mini. takes alot more work to get the sunroof in and roof smooth.

just keep cutting closer to the line until the open air roof fits.

Do it with a jigsaw, its what they're designed for!

Its vital to do it in one cut dude, don't cut it too small, then grind it to size as it will give you a rough, wonky edge. Also, if you did it in two hits with a jigsaw (still a No-No), you'll run the risk of bending it on the second go with most of the stregnth gone. Measure what radius corners are and then practice cutting the same radius out on some scrap metal.

Jigsaw, one hit.

plasma cutters are fun

Ben, i agree.. when theres a hole there and nothing filling it

BUT, as soon as the sunroof is in, and the frame is tack welded in... it aint flexing for shit dude. I'm 99% positive it will end up being stronger than standard.

I'm going to put some little braces in anyway.. but i bet it doesnt need it.

id have said a jigsaw tbh.

iv cut virtually perfect circles out of sheet metal with them.

get some decent metal blades, maask around where your cutting so you dont scratch it where youre dragging it along, and keep pressure on so it doesnt chatter and bend/dent your roof, but not too much so your bending it anyway haha

Let me do it, I'm fucking ace with a jig-saw

a lad i mechanic for at racing....his dad has a cordless grinder, and he uses it for any possible reason whatsoever haha

Cheers for the advice btw guys

Think I'll go for the jigsaw. I've got a decent set of blades.. only ever used the wood ones though so got loads of fresh metal ones that are hungry for polo roof

Less sparks also using the jigsaw... grinder was bound to start a fire inside the car

Take it your gonna be doing this very soon then?

Will this ever happen Toby? Plus Id avoid cutting holes in the roof until you've repaired that fucking great tear in your open air rag

Will this ever happen Toby?

This

Will this ever happen Toby? Plus Id avoid cutting holes in the roof until you've repaired that fucking great tear in your open air rag

Check my thread dude... bought another with just 2 tiny little rips in.

I'm an openair whore

But yeah, I'm finding myself bored.

Wont do it till after xmas though, I'm using my car a lot atm. more than usual. Wait for everything to quieten down in the new year and ill attack it then i think.

I´d advice you something like this:

http://www.ebay.de/itm/Nibbler-Wellblech-M...=item51901685d6

http://www.ebay.de/itm/Druckluft-Blechnibb...=item2c5f4e4656

Dont know, the british name vor " Nibbler" or Knabber"

The upper one works with every electric Drill, the Lower one with compressed air.

This stuff Stamps small circels out of the Metal.

Had one sometime before, worked quite finde.

oh god

You not impressed Chris?

Cheers Polo4l, looks interesting.

id be careful with the jigsaw mate - it will bounce around and dent and warp the roof. id do the 4 hole cutters in the corner with a jacked up piece of wood underneath for support and then join them using 0.8mm grinder cutting disks -----slow as fook! and remember to support the roof as you cut it or it will pull the other piece down and bend it. - have you got a piece of 6n roof?

did you do the measuring in the end? will it fit or is it needing to be cut down