the uber-tool to perform this is a Greenlee Chassis punch

 

[quote name='banzaitoyota' date='Jun 2 2005, 07:13 AM']the uber-tool to perform this is a Greenlee Chassis punch


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I thought about that too, but I didn't know they made them that big, I have the set up to and including the 1 1/2" chassis punch.

 

I tell you what. The Greddy kit is a deal. Im slowly making my way up to that price.



$200 core

$200 piping

$85 couplings/reducers/clamps

$60 brackets

$75 battery relocation

$50 for passenger side welds



still have to get the driver side welds and modified tb adapter.

 

[quote name='89 Rag' date='Jun 2 2005, 06:43 AM']I thought about that too, but I didn't know they made them that big, I have the set up to and including the 1 1/2" chassis punch.


[/quote]



You think electrician's use 1 1/2' conduit for their main power feeds into junction boxes?

You can get them as big as you need.



I thought about suggesting one, but due to their cost and availability, decided against it.



They are also not the best tool to use when the sheet metal is not completely flat.

 

[quote name='scathcart' date='Jun 2 2005, 07:25 PM']They are also not the best tool to use when the sheet metal is not completely flat.


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Which is certainly isn't in this case. That was pace-breaker when I was drilling my holes. I can honestly say it turned out ok. I just need to primer the areas I cut so it doesn't rust, then protect the edges again.

 

After you file off the rough edges you can use some door edge guard and some bionic sealant to protect against anything getting cut or scraped that otherwise wouldn't be.



Where is this available 89 Rag?

 

[quote name='scathcart' date='Jun 2 2005, 08:25 PM']You think electrician's use 1 1/2' conduit for their main power feeds into junction boxes?

You can get them as big as you need.



I thought about suggesting one, but due to their cost and availability, decided against it.



They are also not the best tool to use when the sheet metal is not completely flat.


[/quote]



lol, I din't say they didn't make them, I just wasn't aware of one larger than that.





[quote name='SidewaysFC' date='Jun 3 2005, 04:52 AM']After you file off the rough edges you can use some door edge guard and some bionic sealant to protect against anything getting cut or scraped that otherwise wouldn't be.



Where is this available 89 Rag?


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You should be able to source it at any of your local auto accessories outlets. Also any auto dealer might stock it or at least send you in the right direction to get it.

 

[quote name='89 Rag' date='Jun 3 2005, 06:48 AM']lol, I din't say they didn't make them, I just wasn't aware of one larger than that.


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I'm just ribbing ya.

Greenlee is most well-known for making tools for electrical use... their "chassis-punches" are just double-dutying from their normal use in knocking out electrical boxes to fit electrical metallic tubing connectors. That is the reason they are available to fit in such obscure sizes, since the connectors are always just slightly larger than the actual pipe.... so a 3" punch will make something like a 3.15" hole.