Butt Joint Question

[Matt@RFR]

Got it. Yeah, I'd definetely tie up that lap weld. You don't have to weld it solid, but putting, say, a 1/2" weld on both ends would be a good idea.

DONT LAUGH! I lost my body hammer when we moved

What's a body hammer?

Concerning putting that 4" hole through double wall, a hole saw will do it, as well as a jigsaw, and plasma's cutt double wall reasonably well.



If you do it with a jigsaw or equivalent, drill a bunch of holes tangent to your cut line, and then saw inbetween each hole. Lots faster that way.

[JoshStratton]

If you do it with a jigsaw or equivalent, drill a bunch of holes tangent to your cut line, and then saw inbetween each hole. Lots faster that way.

Oooooo great idea!

I wasnt sure how I was going to manage to get it cut out. I have a jig saw, but I was just going to get some more cut-off wheels for my Dremmel.

Ok, so here is ANOTHER question

When I cut the hole out, I know it wont be very smooth. Most of my cuts are kind of rough. How do you smooth something like that out when it is in the middle of a piece and keep it looking like it was punched out all nice and purty-like?

Here is an example of what I mean, sorta.



Those edges inside need cleaned up and they are hard to do. I may get a tail panel from a 69 like Travis (i think) suggested and weld the holes in, but just in case, I would like to figure out how to smooth these down.

[Matt@RFR]

Go to www.mcmaster.com and type look at the top of page 2523. Those stones have a 5/8-11 female thread and they simply screw on to your angle grinder. I've got many, many miles behind those damn things, and they work really well.

Either that, or just use a die grinder with a double cut carbide cutter. The grinding stones are much easier to control though. And faster.