What tool do I need to clean up this cut?

[FastKat]

I recently cut a hole in the transmission tunnel of my old Jaguar to accommodate some new shifter linkage. I used a 4 1/2" angle grinder. It was a little bulky and the steering wheel over my head made it tough for me to get good straight cuts. I now want to clean up these cuts with something like a Dremel tool rather than at a tool with a 90 degree cutting wheel, like an angle grinder.

So I have a Dremel and I was thinking about using that. I don't like it very much because it seems to wear out bits quickly. Is there any bit I can put in the Dremel shank that would be suitable for this job? Would it last more than 30 seconds?

I was thinking about going out and buying a full size die grinder, but I don't really want to spend the money to have it for this one job.

Any suggestions would be helpful. Eventually, I am going to weld some sheet steel over part of the hole, and put a removable panel on the other part of the hole.

 

[930dreamer]

I'd think the smaller size of the Dremel would work better in that small space. I use the thicker cut off/grinding wheels. Any pics of the whole Jag?

 

[Cougar]

How about a carbide bit in the Dremel.

 

[FastKat]

Thanks for the feedback guys.

Here's a link to the webpage for the Jag. The newest pics are at the bottom of the page. I have some new pics that I haven't uploaded yet.
http://www.buyrcars.com/jag.htm

So a carbide bit is what I want? How well do those hold up? Is that something like a sanding drum, but made of carbide steel?

 

[omr]

Thanks for the feedback guys.

Here's a link to the webpage for the Jag. The newest pics are at the bottom of the page. I have some new pics that I haven't uploaded yet.
http://www.buyrcars.com/jag.htm

So a carbide bit is what I want? How well do those hold up? Is that something like a sanding drum, but made of carbide steel?

that link just played hell with my computer ,click with caution

 

[Altec]

If it was me, I'd probably use a jig saw/air reciprocating saw with a cut down blade. Just open the entire thing up a tiny bit more. Then a flat file, or a flapper wheel to smooth the edge.

If you want to use a dremel, double up your cut off wheels, and if it gets hot, take a break... I'd probably go for a 1/4" die grinder with a cut off wheel myself if I wanted to go that route. A die grinder is a valuable tool to have. It can be used for grinding, cutting, wire wheels, polishing, and whatever else you want to spin fast...

 

[NASTYZEN]

Tin snips?

 

[gorilla]

I would use a small round grinding stone in a small die grinder or an electric drill. You don't want to use a carbide burr they can be difficult to control on thin materials and you have too much stuff in that area that could be damaged. A Dremmel will do the job but it will take you a while.

 

[Frank The Plumber]

If it was me, I'd probably use a jig saw/air reciprocating saw with a cut down blade. Just open the entire thing up a tiny bit more. Then a flat file, or a flapper wheel to smooth the edge.

If you want to use a dremel, double up your cut off wheels, and if it gets hot, take a break... I'd probably go for a 1/4" die grinder with a cut off wheel myself if I wanted to go that route. A die grinder is a valuable tool to have. It can be used for grinding, cutting, wire wheels, polishing, and whatever else you want to spin fast...

How about a small air belt sander. Other wise a brand new set of directional tin snips could be helpful.

 

[airbuff101]

Gee, I would think a couple files followed by a sanding block or coarse paper wrapped in leather would make quick work of it. I'd wear welding gloves and have at it with 60g then 100g paper. Swivel deburring tools work great to rough off the burrs first.
I've never had much real use for dremels myself....buzzy little bastards... with a homeowner feel..........

airbuff

 

[Altec]

How about a small air belt sander. Other wise a brand new set of directional tin snips could be helpful.

Good idea! I just don't use them too often. Not sure how long belts last?

I would say snips, but the metal looks pretty thick, combined with the limited space. Could turn out worse then it did before...

 

[Zengineer]

Tin snips?

Agreed.

 

[FastKat]

Thanks for the suggestions. I don't have much in the way of sanders, either... just an orbital air sander with fine grain paper, suitable for body work.

I might look into some grinding stones. I also have a straight air-powered cut-off wheel. Maybe I can get in from the passenger side, lean over the center console, and clean up the cuts sort of upside down. I'm no artist with cut-off wheel, but I can cut pretty well left-to-right. I might have to try and take the shield off so I can see what I'm doing.

I planned on using files to get rid of the sharp edges. I just thought that a rotary tool (like a Dremel or die grinder) would help me take a little more material off so I could do less with a cutting wheel and more with a rotary tool.

 

[KenS]

Right angle air die grinder with a 34-grit Roloc. The Dremel will take you all day.

 

[Rentawrench]

i agree with Ken . Is tran still going to be in the way ?

Grinder like this: http://www.harborfreight.com/air-tools/grinders/air-angle-die-grinder-32046.html

and http://www.harborfreight.com/complete-sanding-disc-kit-43029.html

This is a Must have tool once you have it , Grinding , Gasket removal, Clean up for welding .

 

[burnitwithfire]

90° die grinder with cutoff disc. I've used one quite a few times to straighten cuts and it works well. A carbide bit or stone will get metal off but it will be extremely hard to make a straight edge. With the cutting discs you can just open up that hole a little bit to get it straight.

It was one of the most used air tool in my toolbox when I worked in a bodyshop. Good for cutting metal, wood, plastic and the roloc discs are really great.

 

[Brad54]

Get a cheap HF right-angle die grinder, and Roloc disks. You THINK you won't use them often, but once you have them, you'll wonder how you ever lived without it.

The horse is out of the barn already for this next suggestion, but others reading it might benefit from it: When I have to cut a panel out like that (I did it for the floor shifter on my '57 Chevy, for instance), I like to mark all my cut lines, and then drill a hole at all the corners, either a half-inch drill bit, a step-bit, or a 1-inch hole saw. Once all the corners are cut (radiused), then I just connect the dots with straight lines using the cut-off wheel.

-Brad

 

[Ritter4.0]

Right angle air die grinder with a 34-grit Roloc. The Dremel will take you all day.

This. And knock it out in a 1/2 hour to 45 min. And buy a halfway decent die grinder, because once you have it you will find all sorts of uses for it. They can make a lot of jobs easier if you have the compressor to back them up.

 

[KenS]

And buy a halfway decent die grinder...

AirCat ACA6255R

 

[hunter1151]

A straight and right angle DOTCO die grinder is a must have. You won't like the price though. With a 3 inch pad, 3M, and Standard make a huge number of sanding and blending abrasives.

 

[jamesemery728]

Gee, I would think a couple files followed by a sanding block or coarse paper wrapped in leather would make quick work of it. I'd wear welding gloves and have at it with 60g then 100g paper. Swivel deburring tools work great to rough off the burrs first.
I've never had much real use for dremels myself....buzzy little bastards... with a homeowner feel..........

airbuff

+1 on the deburring tool, if you are going to cover it anyway then it does not have to be too pretty. The swivel deburring tool will clean up the edges so you don't cut your hands on them.