1940 Ford Pickup recessed tail lights
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[[File:8_Grid_lines.JPG]] | [[File:8_Grid_lines.JPG]] | ||
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| + | Measure out the pilot hole centers for both sides of the radius of the light lens, in this case the dimension is 2" so we measure 1 inch from the outside grid lines vertical and horizontal and obtain a center pilot hole for our drill mandrel. Center punch this hole before you drill it. | ||
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| + | [[File:9_center_lines.JPG]] | ||
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| + | Drill the pilot holes and set up the punch holes. I am making a 1/2" pilot hole, followed by a 1" punch hole. | ||
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| + | [[File:10_pilot_holes.JPG]] | ||
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| + | I will then increase my hole punch to 2" and take the rest of the excess metal out. Doing it all in one motion may warp the panel, and extra body work may be required. | ||
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| + | [[File:11_hole_punch.JPG]] | ||
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| + | Make certain that your hole punch is aligned with both horizontal and vertical grid lines before you punch it through. | ||
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| + | [[File:12_hole_align.JPG]] | ||
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| + | When both holes are done, you then have to remove the metal in between both circles using a thin cut-off wheel, shears or air nibbler. This is a cut and file to fit operation and the end product is in your hands entirely. Fit the light lens to the hole to obtain the best fit possible using a selection of round and flat files, grindstones, and die grinder, working slowly and carefully, measure with your lens often. | ||
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| + | [[File:14_initial_fit.JPG]] | ||
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| + | [[File:15_finish.JPG]] | ||
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| + | It can take a couple of hours to go from rough opening size to final finish to a pair of tail lights. Make sure to spray the edges of the cut opening with a good primer and sealer to avoid any rust problems. | ||
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| + | [[File:16_pair_of_lites.JPG]] | ||
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