Difficulty Level

Tools/Supplies Needed:

• cardboard
• tape
• felt tip marker
• drill
• step drill bit
• Dremel/rotary tool
• cutting disks
• drum sanders
• paint

Procedure:

• using a piece of thin cardboard, similar to what is found on cereal boxes we will use this to create our template
• laying the piece of cardboard on the panel with the hole, use a felt tip pen to mark out the hole alone with an edge of a panel or any other reference points we can use to hold the cardboard template against
• once you've traced out the area, next cut the area of the cardboard which aren't need with either scissors or a razor knife
• in order to mirror the hole, you have to flip the cardboard template over
• if you're cutting onto an existing painted panel, tape off using painters tape
• this will ensure the paint doesn't chip when you're cutting it and the marker won't stain the paint surface
• mount the cardboard template on, ensuring everything lines up to your satisfaction and then use some tape to hold it into place, then trace out what you will be cutting
• remove the template, but leave the taped areas which you will be cutting in place
• you can use a variety of methods for cutting, in this video I used a step drill bit, along with a small abrasiveness cutting blade for the Dremel/rotary tool
• roughing out the hole, I then used a stone wheel on the Dremel/rotary tool in order to enlarged the hole and cut out any rough edges
• once you are fairly close to the cutout dimension, finish up with a drum sander tool for the Dremel/rotary tool moulding
• after you are satisfied with the newly cut piece, you are ready to remove the tape
• if this was a painted surface, you should touch up the bare metal so it doesn't rust in the future with some touch up paint