Chassis Holes

[newkitman]

Building my TD and was wondering what you folks who built your VW based TDs used to drill the 2-inch holes for the pedal cluster and shifter in the chassis tunnel. I have a hole saw kit that runs up to 2 1/2- inches but I’m not sure it’ll cut thropugh the tunnel. Should I purchase another one? Because I know this one will not have any teth after one hole. Thanks in advance.

Allen Caron
VW based 53MGTD - "MoneyPenny"
"If one thing matters, everything matters" - from the book The Shack

[Paul Mossberg]

Great question!

 

And brings back some funny memories.

The advice: I believe I cut the holes for the pedal cluster and relocated shifter with one hole saw. It was complete trash by the time I was done. If you want to keep your tool-kit complete, just buy a two inch saw that fits your mandrel. They are pretty standard.

 

The funny part:

 

The noise was unbelievable! 

 

I was building my Duchess in a one car garage at my mom & dad’s condominium complex. The garage faced out across the driveway, aimed directly at the terraces of the units behind my parents’. And the garage acted like a megaphone, projecting the noise into the facing condos. Security got a LOT of complaints about me that night!

Paul Mossberg
Former Owner of a 1981 Classic Roadsters Ltd. Duchess (VW)
2005 Intermeccanica Roadster

If you own a TDr and are not in the Registry, please go to https://tdreplica.com/forums/topic/mg-td-replica-registry/ and register (you need to copy and paste the link)

[Mike]

Allen I didnt build my kit, but in the shop where I work I have seen hole saws used to cut steel plate up to 1/2″. I am not saying yours wont, but most  hole saws that come in kits should be used for wood or aluminum. I would get a single saw like Paul suggested. A good place to get a quality hole saw would be some bolt and screw supply house in your area or possibly Lowes. Expect to spend around $20.00. Try to keep your drill RPM at 150 or below on a 2″ diameter saw and use a cutting oil or in a pinch WD-40. A quality saw will cut many holes. Expect a lot of smoke from the cutting oil and maybe use a glove on your drilling hand as the cutting oil will heat up enough that you will think someone is frying bacon and you are catching the splatter. Oh yes and the noise will make your neighbors think you are skinning a cat!

Mike N Scarlett2012-05-29 18:00:18

[newkitman]

Paul and Mike,

Thanks for the info. 100 rpm on the drill should be fine. I have earplugs and ear protectors so the noise shouldn’t be a problem. PLUS…I only have my back yard and sound will dissipate easily. Looks like I have some retail therapy to accomplish tomorrow at lunch.

Allen Caron
VW based 53MGTD - "MoneyPenny"
"If one thing matters, everything matters" - from the book The Shack

[newkitman]

Ha-ha! Hole drilled about 20 minutes ago.

Neighbor…”Hey Al. What in the hell are you doing with all squeeling going on over there?”

Me…”Squeeling! What squeeling?” 

Allen Caron
VW based 53MGTD - "MoneyPenny"
"If one thing matters, everything matters" - from the book The Shack

[Paul Mossberg]

Excellent!

I like to hear good news!

Paul Mossberg
Former Owner of a 1981 Classic Roadsters Ltd. Duchess (VW)
2005 Intermeccanica Roadster

If you own a TDr and are not in the Registry, please go to https://tdreplica.com/forums/topic/mg-td-replica-registry/ and register (you need to copy and paste the link)

[Author]

Posts