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  • 1979 - 1995 (Fox, SN95.0, & 2.3L) -General/Talk-

Power Pipe hole cutting methods....How'd you do it?

  • Thread starter Thread starter bottlfed92
  • Start date Start date Feb 22, 2007

bottlfed92

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Aug 16, 2004
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Feb 22, 2007
#1
  • Feb 22, 2007
  • #1
I have got a few ideas from a couple guys (MansonOzz, 87TTop) on how they cut their holes. Wondering how everyone else has done theirs .
Post pics of the process, if you have them. How big was the hole you cut?
Thanks guys.

~Jeff
 

blackened88lx

Active Member
Aug 9, 2006
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Feb 22, 2007
#2
  • Feb 22, 2007
  • #2
I helped my buddy (bentley429) do the one in his car. I will direct him to this thread if he doesn't find it first. He does have pictures. I don't remember the exact size but I think it was around 4-1/2"?? We just marked out a circle and cut it using a jig-saw and a metal bit, then touched it up using a die-grinder with a grinding stone. It came out excellent.
 

bottlfed92

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#3
  • Feb 22, 2007
  • #3
That sounds like a good method. Thanks. See if you can get ahold of your friend.

Jeff
 
B

bentley429

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Nov 25, 2004
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Feb 22, 2007
#4
  • Feb 22, 2007
  • #4
bottlfed92 said:
That sounds like a good method. Thanks. See if you can get ahold of your friend.

Jeff
Click to expand...

Yep, thats how we did it. Piece of cake to do, and it was 4 1/2" around though I did grind out a hair more so I had abit of play. Heres before and after pictures:

 

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91ghp5.0

Active Member
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Feb 22, 2007
#5
  • Feb 22, 2007
  • #5
Any pics with the powerpipe installed?
 

bottlfed92

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#6
  • Feb 23, 2007
  • #6
bentley429 said:
Yep, thats how we did it. Piece of cake to do, and it was 4 1/2" around though I did grind out a hair more so I had abit of play. Heres before and after pictures:

Click to expand...


So, basically, the center of the existing hole is the center of the new hole? That should be really easy. I thought that's how it went. Thanks for the pics. I'll post a pic of mine on Monday, after it's cut .

~Jeff
 

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B

bentley429

Banned
Nov 25, 2004
528
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Feb 23, 2007
#7
  • Feb 23, 2007
  • #7
bottlfed92 said:
So, basically, the center of the existing hole is the center of the new hole? That should be really easy. I thought that's how it went. Thanks for the pics. I'll post a pic of mine on Monday, after it's cut .

~Jeff
Click to expand...

Exactly, like I say its easy just take your time. I can post pictures of the powerpipe installed...in afew weeks when the car has a engine in it haha.
 

blackened88lx

Active Member
Aug 9, 2006
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Feb 23, 2007
#8
  • Feb 23, 2007
  • #8
Bottlfed, are you painting the bay afterwards? or cutting the hole with it painted?? I remember you have an incredible engine bay, and If it's already painted I'm not sure if the jig-saw would cause the paint to chip. Just a thought. We painted the bay afterwards obviously so it wasn't a problem, but it's something you might want to watch out for.
 

bottlfed92

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Aug 16, 2004
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#9
  • Feb 23, 2007
  • #9
blackened88lx said:
Bottlfed, are you painting the bay afterwards? or cutting the hole with it painted?? I remember you have an incredible engine bay, and If it's already painted I'm not sure if the jig-saw would cause the paint to chip. Just a thought. We painted the bay afterwards obviously so it wasn't a problem, but it's something you might want to watch out for.
Click to expand...

I'm redoing the entire bay. Basically, looks like a new motor.
I have a new (hand RE-polished ) PP intake, ACCUFAB TB and spacer (beautiful piece), AFM Power Pipe, Tall plain polished aluminum valve covers, billet PS pulley (to finish off the collection..LOL) and I've removed the STB. I have to fill in the large factory induction hole and the STB mounting holes, anyways.
So yes...I will respraying the whole engine bay afterwards. Thanks again.

Jeff
 

from6to8

There's suction so I used that end O_O
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#10
  • Jan 19, 2026
  • #10
bottlfed92 said:
So, basically, the center of the existing hole is the center of the new hole? That should be really easy. I thought that's how it went. Thanks for the pics. I'll post a pic of mine on Monday, after it's cut .

~Jeff
Click to expand...
i know a super old thread lol but to answer your question it seems it depends on what supercharger you have and where the inlet will sit. With my V3 that I'm about to cut the hole for, the orientation for mine will put the hole closer to the strut tower I'd say from the hole in this pic, probably 2-4 inches to the right....
 

Noobz347

Stangnet Facilities Maint Tech... Er... Janitor
Admin Dude
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Jan 19, 2026
#11
  • Jan 19, 2026
  • #11
from6to8 said:
i know a super old thread lol but to answer your question it seems it depends on what supercharger you have and where the inlet will sit. With my V3 that I'm about to cut the hole for, the orientation for mine will put the hole closer to the strut tower I'd say from the hole in this pic, probably 2-4 inches to the right....
Click to expand...

Dude hasn't been on since 2011.

I'm pretty sure he's moved on.
 

from6to8

There's suction so I used that end O_O
15 Year Member
Sep 2, 2012
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#12
  • Jan 19, 2026
  • #12
Noobz347 said:
Dude hasn't been on since 2011.

I'm pretty sure he's moved on.
Click to expand...
LOL I'm sure and I didn't check to see when the last time he was on as I usually do I was just checking something online right quick before I cut my hole
 

AeroCoupe

lube between the nut and the face. I know my lubes
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#13
  • Jan 19, 2026
  • #13
"quick before I cut my hole"....if you didn't already have a good CT...
 
Reactions: General karthief

from6to8

There's suction so I used that end O_O
15 Year Member
Sep 2, 2012
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#14
  • Jan 20, 2026
  • #14
AeroCoupe said:
"quick before I cut my hole"....if you didn't already have a good CT...
Click to expand...
Huh lol?
 

from6to8

There's suction so I used that end O_O
15 Year Member
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#15
  • Jan 20, 2026
  • #15
AeroCoupe said:
"quick before I cut my hole"....if you didn't already have a good CT...
Click to expand...
Lol
 
G

GOvert

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Jan 27, 2007
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Jan 20, 2026
#16
  • Jan 20, 2026
  • #16
Hole saws work great if it is a "virgin" hole that you are making. However, using a hole saw in to enlarge an existing hole is very difficult. If you were to fasten a scrap piece of wood or even 1/8" aluminum sheet to the back side of the existing hole, then the wood lets you make a new "pilot bit" hole and keeps the hole saw steady. I have done this on 1970 Mustang headlight bucket "cups". The halogen light upgrade needed bigger holes for the backside of the fixture to sit down into the cup properly. Apparently, this technique works well on thicker metal too like brake backing plates. At ~3:15 into the video, a guy is using a hole saw to enlarge the hole in his backing plate.
Big hole saws tend to cost several dollars, and it is great if you can borrow one as large as 4.5". It looks as though the jigsaw worked well on the thin metal.
Enlarging hole in brake backing plate
 

from6to8

There's suction so I used that end O_O
15 Year Member
Sep 2, 2012
1,893
141
94
Jan 20, 2026
#17
  • Jan 20, 2026
  • #17
GOvert said:
Hole saws work great if it is a "virgin" hole that you are making. However, using a hole saw in to enlarge an existing hole is very difficult. If you were to fasten a scrap piece of wood or even 1/8" aluminum sheet to the back side of the existing hole, then the wood lets you make a new "pilot bit" hole and keeps the hole saw steady. I have done this on 1970 Mustang headlight bucket "cups". The halogen light upgrade needed bigger holes for the backside of the fixture to sit down into the cup properly. Apparently, this technique works well on thicker metal too like brake backing plates. At ~3:15 into the video, a guy is using a hole saw to enlarge the hole in his backing plate.
Big hole saws tend to cost several dollars, and it is great if you can borrow one as large as 4.5". It looks as though the jigsaw worked well on the thin metal.
Enlarging hole in brake backing plate
Click to expand...
yeah I borrowed one from work and at it wasn't super easy but not super hard. At the angle I was cutting at because the side of the wall wasn't flat and had a hump, the bit was long enough to bit and make the hole and the top of the saw blade caught first and it kept stopping some and I had to pull back and let it start slightly before touching the metal. It wasn't so bad and took about 5 mins ish mostly because of those small issues...
 

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