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#1
Tim

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I need to replace doors on my 1994 spec miata. I have found 2 nice donors. What do those of you in the now suggest I use to cut out the inside part of the door? Is it better to take to someone or do it myself.

#2
Johnny D

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If you didn't like any of these suggestions, take it someplace.
http://mazdaracers.c...st=0
J~
2011 NASA Western Endurance Racing Championship E3 Champ
We have a Winnah! - Won their 1st race... Congratulations! Beta-Tester - Assisted us with beta testing the website. Donor - Made PayPal donation Bona fide - A bonafide Spec Miata driver Novel Approach - When a paragraph simply won't do... Survive the 25, NASA Thunderhill - Survive the 25, NASA Thunderhill Instigator - Made a topic or post that inspired other Make it Rain - Made Paypal donation of $100+

#3
Tom Hampton

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If you want to see how I did it.

http://www.tomhampto...t-of-no-return/

-tch
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#4
Bench Racer

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Buy a 10,000 stroke per minute air saw from Harbor Freight for approx $30.00. Assuming you have an air compressor. Draw lines on the door,cut to the lines, draw file & your complete.
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#5
dstevens

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A fab shop can plasma cut it for probably 50-60 bucks. Bring it to Vegas and I'll do it for free... :lol:

If you are going to cut it mechanically most fabricators that couldn't use plasma (or O/A) would use a cut off wheel. Saw don't work as well as abrasive cut off wheels on gauge stock. Get the orange HF 4 1/2" angle grinder (avoid the blue one, it's crap). I bought an orange one about 5 years ago when I got back into fab. I still use it but it can bog so I've got 4 Dewalts. People that do a lot of fab will load each grinder with a different media so they don't have to change wheels.

#6
Greg Kimble

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The saw David mentions above (and I mentioned the first time you asked) is on sale in the new HF ad for $12.99.
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#7
dmathias

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Air chisel w/ a sheet metal bit works great. Helps to have some practice.
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#8
Bench Racer

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The saw David mentions above (and I mentioned the first time you asked) is on sale in the new HF ad for $12.99.


Thank you Greg.

Others, I've sawed doors by many different processes & the 10,000 stroke per minute saw & then draw filing (fine tooth file) is the quickest, easiest , cleanest process :excl: :excl: :excl:
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#9
dstevens

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I can cut gauge at about 80 inches a minute, drop cut, no dross, no other finishing required. :)

#10
Alberto

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Does a Dremel work for this? I need to clearance some of the door sheet metal for my window net. I don't own any air tools. Heck, I'd probably be dangerous with air tools...
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#11
dstevens

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How big is the Dremel? You are probably going to need something with a bit more umph. May want to look at an electric Sawzall or angle grinder. Good quality around 100 bucks each though places like CPO outlet have refurbeds for a pretty good deal. Difficult for me to say to you which one to get first. I think they are both good to have. With the angle grinder you can wire wheel, flap sand or abrasive cut. The Sawzall is good for more all around the house projects, wood, demo work. I just built the Mrs a raised bed planter with mine. If you don't have the dough but have some time you can do it with a hacksaw and file. Pack a lunch, though... :D

#12
Johnny D

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How about a jigsaw with a blade for metal? Just asking.

Tim, A question I have to ask....
If that is your black car, why are you replacing the doors?

Damage? Bang them out, bondo, sand, paint?

Also Barry H is a member here and has a shop where you're at. He may be able to help.
J~
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We have a Winnah! - Won their 1st race... Congratulations! Beta-Tester - Assisted us with beta testing the website. Donor - Made PayPal donation Bona fide - A bonafide Spec Miata driver Novel Approach - When a paragraph simply won't do... Survive the 25, NASA Thunderhill - Survive the 25, NASA Thunderhill Instigator - Made a topic or post that inspired other Make it Rain - Made Paypal donation of $100+

#13
dstevens

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It would work. Use the right blade.

http://www.lenoxtool...talJigsawBlades

As far as saws go, that HF body saw is the better choice but I've never seen an electric one though I'd imagine they are out there.

They are out there, doesn't spec as well as the air saw does...

http://www.harborfre...r:referralID=NA

#14
Alberto

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How big is the Dremel? You are probably going to need something with a bit more umph. May want to look at an electric Sawzall or angle grinder. Good quality around 100 bucks each though places like CPO outlet have refurbeds for a pretty good deal. Difficult for me to say to you which one to get first. I think they are both good to have. With the angle grinder you can wire wheel, flap sand or abrasive cut. The Sawzall is good for more all around the house projects, wood, demo work. I just built the Mrs a raised bed planter with mine. If you don't have the dough but have some time you can do it with a hacksaw and file. Pack a lunch, though... :D



Its a regular hand held Dremel.

I really don't feel like spending $100 on something I'll use once. I'll figure something out. I might just use my power drill and the dremel to make something work. :)
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#15
Johnny D

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Its a regular hand held Dremel.

I really don't feel like spending $100 on something I'll use once. I'll figure something out. I might just use my power drill and the dremel to make something work. :)


You'll go through a lot of cut off wheels and take forever.
J~
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We have a Winnah! - Won their 1st race... Congratulations! Beta-Tester - Assisted us with beta testing the website. Donor - Made PayPal donation Bona fide - A bonafide Spec Miata driver Novel Approach - When a paragraph simply won't do... Survive the 25, NASA Thunderhill - Survive the 25, NASA Thunderhill Instigator - Made a topic or post that inspired other Make it Rain - Made Paypal donation of $100+

#16
Tom Hampton

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Its a regular hand held Dremel.

I really don't feel like spending $100 on something I'll use once. I'll figure something out. I might just use my power drill and the dremel to make something work. :)


You don't have an angle grinder with a cutoff wheel? I don't know how I'd survive without one!!! Seriously, I have this one:

http://www.amazon.co...r/dp/B0013Y9OLI

its $40 with a cutting wheel, and a grinding wheel. You will need more cutting wheels. I used one per door.

-tch
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#17
Alberto

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You don't have an angle grinder with a cutoff wheel? I don't know how I'd survive without one!!! Seriously, I have this one:

http://www.amazon.co...r/dp/B0013Y9OLI

its $40 with a cutting wheel, and a grinding wheel. You will need more cutting wheels. I used one per door.



I've never needed one before. If its only $33, it might be worth getting one.
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#18
dstevens

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That's a good price. It's a bit on the small size, only 5 amps but should suit your needs. I've got 5 4/12" and I'm looking for 6" Metabo though I probably do more fab than many here.

http://www.metabo.us...er.24652.0.html

#19
Tom Hampton

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More is not always better. I've built the whole car with that tool, including the cage. I have never had it bog down, or not be enough tool for the job.

Also the smaller tool didn't take my finger off like a bigger tool might have.

With angle grinders, free handing is necessary quite often, and is easier with the smaller motors. Those monster 10 or 15 motors can have some weight! They also make an even bigger gyro effect. Fine if you need the power. But, how often is that? Less than once per year for me.

For $35 it really is a steal. I use it for everything. I hardly ever put it away!

Lots of different attachments: grinding wheels, cutting wheels, sanding, knotted wire, etc.

-tch
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#20
dstevens

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The size is more of a duty cycle issue for me. I think a 7 amp or so is a good compromise. For example wire wheeling the deadening off the bottom of the car or flap discing and entire car. I burned up a Dewalt 8 amp sanding the rattle can off the first hobby stock. Which they fixed no questions asked at the local service center.

The 6" is for the trailer revamp project. New dovetail (so the chick car won't bottom out ;) ), new decking, new winch mount, tire rack and toolbox/pit cart. I just did new tie down points with 1/2" D-rings. I work with everything from .083 to 3/8", gauge, tube, angle, flat, plate, so a wider variety works well for me. Stick welding 3/8" and having to grind it flush taxes a smaller unit. And takes a while. ;) I've made a bunch of race related stuff over the last few years.

However, for the first couple of years I used that 5 amp orange HF and it's still going strong, well still going after a brush change. Though it was only 15 bucks, the Hitachi seems like a much better value. If you start using a bigger quantity of media go to your local welding supply. For example, that $14 wire wheel at the big box is $6-7 each, even in onesy-twosy, cut off wheels a couple of bucks and grinding and zirconia flaps at about half what they want at the big box.




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