E30 Zone

I want a neat circular hole cut in my headlight grill as an alternative to removing a headlight.

Anyone got any ideas as to how to cut the whole and what with?

The grill is a pretty chunky bit of plastic

Would a drill attatchment like this work?-

they should work ok, but go easy as its only plastic

I was thinking that the grill may vibrate in the vice too much using one of those and crack or i'll slip and scratch the whole thing though

Ive got a spare to practise on so I might give it a go and see what happens

try variable speeds to see which will be best

you might need to put a re-enforcing ring around the hole to stop the bars flapping around.

Will be interested to see the result!!!

oakey wrote:I want a neat circular hole cut in my headlight grill as an alternative to removing a headlight.

Anyone got any ideas as to how to cut the whole and what with?

The grill is a pretty chunky bit of plastic

Would a drill attatchment like this work?-

yes but try to gently clamp it between 2 bits of plywood or similar it to stop the hole cutter from jumping about

Just cover it in duct tape.

I can see it breaking the grill, for a holesaw to work properly the centre drill needs to locate into whatever your cutting, otherwise the saw will jump about all over the place

Couldn't you make some sort of jig for it?

DanThe wrote:I can see it breaking the grill, for a holesaw to work properly the centre drill needs to locate into whatever your cutting, otherwise the saw will jump about all over the place

Good point, best use a light sabre.

DanThe wrote:I can see it breaking the grill, for a holesaw to work properly the centre drill needs to locate into whatever your cutting, otherwise the saw will jump about all over the place

which is why i suggested previously to gently clamp the grill between to pieces of plywood or similar.

I would start on the back of the grill first to see how it goes,
Also looking at them cutting tools i would probably start with the drill in reverse so the teeth dont snatch and snap the fins to bits and cut a hole in your leg or arm, although i wonder if a oil pressure guage would be any good to fit in the slot and check your blood pressure??

How big do you want the hole?

heat one of these up really hot with a heat gun and it will make a good hole, a little sanding will clean up the entry.

http://www.cromwell.co.uk/KEN5181596K

I'd use a Dremel cutting wheel to cut a rough hole, then finish it off with a Dremel sanding wheel. Use tipex or something to mark your inner circle, and then sand until the tipex is no longer visible.

Get a block of polystine and cut some strips so it slots onto the grill to reinforce it while you cut/sand.

Using a core drill/hole saw will end in tears methinks. A Dremel will make light work of it.

As fuzzy said, get a piece of wood, but cut the hole through the wood before you fix it to the grill, that way you'll be able to line where your going to cut. Keep the plastic warm to stop it from shattering too!