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3x3 mod...what did you use to cut out the hole?

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doing the 3x3 finally and was just curious what tool you guys used to cut out the whole.

thanks -

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Drilled 4 holes in the top...Each hole in

the corner of the square I was going to

cut. Then I used an exacto knife to cut between

the holes. Careful with the knife when cutting

as you'll need to put quite a bit of pressure

while cutting. If you have a portable hand

jigsaw that would be easier but just make

sure you block off the opening to the carb

so as not to get any plastic pieces in it...

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Haven't done it on the DRZ yet, but on the WR, I marked my cutting lines, drilled 1 hole and heated up a bolt with a torch, inserted the bolt in the hole and ran the hot bolt along the cutting lines. Does a nice job, and than you can clean it up with a file.

Not saying this is better, but giving you another option.

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use a 1" hole saw for a drill to cut the 4 corners, then cut from hole to hole with a drywall saw on the outside edges. cheap hand saw (about 5 bucks)made for cutting holes in drywall for switch and recepticle boxes. I placed masking tape on the top of the box to outline everything first with a pen... then cleaned up the edges with a file... if you don't have or don't want to buy power/torchs that will do it easier.. make sure you remove the filter no matter what you do, or you will be buying a new one... and be careful where the clearance to the bottom is narrow not to cut it too....

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A soldering iron - if you mark the hole and work along a straught edge, it's very neat and accurate. A sharp knife trims up the edges so it looks like it was moulded that way.

Ian

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Drew shape on box, drilled 4 corners with 1/2" spade bit, hand-held hack saw blade to connect the corners, sand paper to smooth edges, shop-vac to clean debris out of airbox.

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If you choose a drill/saw then remove the filter first and stuff a rag into the intake. The goo on the filter loves the plastic bits.

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covered the intake... drilled 4 small holes....then used a bare hacksaw blade...hahah

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