Need to create 1/4" square holes in the

[67CoupeDriva]

inner door panels of my '67 to mount the lower door grilles. It is supposed to use the plastic inserts in the door, which the grilles and then screwed into.

Yes, I could just drill holes and screw them directly in, but it looks like the inserts may provide a little backing to the hollow part of the grille and prevent warping it.

So...any of you guys know how I might go about that? My only thought is a sheet metal punch, but I'd rather not spend $100+ dollars to make 8 holes and never use again.

Also, :OT: , I AM BEGINNING TO THINK THE FARKING WINDSHIELD AND BACKLIGHT WILL NEVER EVER BE WATER TIGHT AGAIN!!!

/end rant.

 

[65fastbackresto]

This could be dumb idea but I`ll risk it

Take a spare round punch and stick it the the grinder and make the end square...make hole with drill, use square punch to make square...

 

[67CoupeDriva]

Not a bad idea, I may try it on something scrap.

Similarly, I think I have a couple of spare bastard files that I could grind down to the right side and not risk stretching the sheet metal.

Thanks for the food for thought.

 

[Realmongo]

If you have the patience, drill holes of the required size and then file the corners.

 

[68stang351]

If you have the patience, drill holes of the required size and then file the corners.

That's what I was thinking.

 

[mustangmike6996]

That's what I was thinking.

this yields the best results.

 

[Couped Up]

Why not use blind nuts?

 

[67CoupeDriva]

Why not use blind nuts?

It looks to me like the inserts may provide a little backing for the grilles; and I was thinking the back isn't completely flat. Now I'm questioning that (they are in the trunk and I haven't looked at them in a few weeks). If they aren't, my level of concern about using the inserts is going to drop dramatically.

I found it odd that the replacement door I installed (to repair damage from an idiot that backed into my car) was from a dlx interior car that ostensibly had them from the factory, and all of the holes except for the light housing ones are just drill holes (no inserts). The assembly manual and fastener kit both call for the inserts.

 

[2+2GT]

If you want the OEM style nylon spacer/nuts to grip the door, the holes must be completely flat, not punched. I drill the holes using the grille as a template, then I insert a square file to evenly open the hole to the correct size. Works quickly, results perfect.

 

[67CoupeDriva]

If you want the OEM style nylon spacer/nuts to grip the door, the holes must be completely flat, not punched. I drill the holes using the grille as a template, then I insert a square file to evenly open the hole to the correct size. Works quickly, results perfect.

Thanks, I think this is the approach I'm going to take. I had someone recommend squaring them off with a dremel cutting attachment too, but in my head anyway the flat file seems like the better choice.

Sounds like you've done a few...is there any reason NOT to use the spacers?