cutting holes for factory AC vents

[rcrahn]

I just received center and ball vents for AC in dash. My cab/dash did not have -AC so I need to cut them in. Can anyone provide some measurements on placement? Not so worried about the center vent but the ball vent tube is angled slightly. It's suppose to rest against the ridge in the dash.
Thanks....

[da-burb]

this should get you part of the way there.
3/8" from door pinch welds.
1/2" up from bottom curve of dash
3 1/2" diam circle + a bump out, you will likely need a tracing of the opening to get it or keep cutting until you get it right.

[WIDESIDE72]

My vintage air instructions include a template to lay on the dash. Not sure if its exactly lkme stock though...

http://www.vintageair.com/DownloadsS...%29%20Inet.pdf

I believe its page 10 and 11
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[da-burb]

The Vintage Air diagram is for their smaller vents, not original AC vents. If you send me your email address I will trace it, scan it, and email you a copy.

[rcrahn]

Thanks! Pictures and dimensions really help. PM sent

[WIDESIDE72]

Originally Posted by da-burb

The Vintage Air diagram is for their smaller vents, not original AC vents. If you send me your email address I will trace it, scan it, and email you a copy.

2-1/2" is smaller than factory? Hmmmm... Did you look at the templates?
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[tinkerdad]

I cut around the holes on a rusted out ac truck and used them as a template, I could be talked into getting rid of them if I still have them

[TBONE1964]

Not sure if you have a welder or access to one but I would cut the part of the dash from a junk A/C cab and weld it in. You could drill the holes with a hole saw but the bend in the dash sheet metal will make it tough to do. Also these were stamped holes from the factory. I am sure if you trace them and drill/cut it will be close and no one will ever know once the vents are installed.

[tinkerdad]

still have them, I'll put them in a box ship them to you. You put them back in the box and ship them back when your done with the postage I paid.

[72 tigger]

I cut holes with a 3 1/2" hole saw in one of my trucks- just go very slow. They turned out great.

[rcrahn]

Originally Posted by tinkerdad

still have them, I'll put them in a box ship them to you. You put them back in the box and ship them back when your done with the postage I paid.

Appreciate the offer. I should be getting an email with the pattern trace from da-burb. If I don't I'll get back to you.

[da-burb]

Rich, I sent you an email as well.

[da-burb]

I was going to attach the pdf of the opening but my pdf is 25kb too large to post.

[rcrahn]

Thanks Kevin for taking the time to trace and send it. I did a quick layout and think it looks good. Now pondering how to cut it cleanly. I'm concerned with such a curved surface a big hole saw will be uncontrollable. It will walk everywhere. Thinking roto zip, but not sure if it will cut metal that thick.
Anyhoo...here's some pics.....

[Toxic Orange]

I would suggest something like this if you have a compressor. I used a sawsall to do mine and it was way too rough to take those tight turns. Used it and an electric die grinder to make the final feathering to my line. Thought I got too big in one spot and had a moment of horror!! Picture is from Harbor Freight. Saw would cost you about 19 bucks. Use lots of tape to protect your paint around your cut. Good luck.

[da-burb]

Rcrahn, looks good. Btw, my 69 LeMans convert would like to borrow the Poncho 400 enigine from the Firebird next to your truck.
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[rcrahn]

Originally Posted by Toxic Orange

I would suggest something like this if you have a compressor. I used a sawsall to do mine and it was way too rough to take those tight turns. Used it and an electric die grinder to make the final feathering to my line. Thought I got too big in one spot and had a moment of horror!! Picture is from Harbor Freight. Saw would cost you about 19 bucks. Use lots of tape to protect your paint around your cut. Good luck.

Thanks, great minds think alike....I was searching around last night and came across this..... it should do the trick. Yes, I recently picked up a Sanborn commercial 60 gallon compressor from CL.

Originally Posted by da-burb

Rcrahn, looks good. Btw, my 69 LeMans convert would like to borrow the Poncho 400 enigine from the Firebird next to your truck.
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Kevin, you never mentioned you have a Lemans vert! You need to send me some pics man. It has a 350 right? Well, the firebird was a father son build, like this truck. She has a 462....

[TBONE1964]

Originally Posted by rcrahn

Thanks Kevin for taking the time to trace and send it. I did a quick layout and think it looks good. Now pondering how to cut it cleanly. I'm concerned with such a curved surface a big hole saw will be uncontrollable. It will walk everywhere. Thinking roto zip, but not sure if it will cut metal that thick.
Anyhoo...here's some pics.....

BTW, that is a very nice 69 bird in the photo. I had a 68 years ago.

[69 MOD]

Nice bird, here's mine...Good luck with the dash I want to do this but am afraid to so you're the test pilot for me lol

[rcrahn]

Originally Posted by TBONE1964

BTW, that is a very nice 69 bird in the photo. I had a 68 years ago.

Thanks - I'm glad to hear there are other Poncho fantatics around this forum. I'm felling the luv....

Originally Posted by 69 MOD

Nice bird, here's mine...Good luck with the dash I want to do this but am afraid to so you're the test pilot for me lol

Well Sir, that is one cool car....
Naw, I'm not afraid of cutting these holes.....it will not be anywhere as nerve racking as when I took a 4" hole saw to the perfectly orginal 400 hood for the hood tach. Now that took some balls....

[rcrahn]

Took the plunge and cut the passenger side hole guys....
Check it out...Thanks again Keving for the template

[Toxic Orange]

Fantastic! When I cut mine (painted already mind you) I almost had a heart attack when I thought I cut them too big. It's a wirerd shaped hole that will fool you visually. Great job!
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[da-burb]

rcrahn, here is my 69 lemans. I haven't done much to it other than wheels AR200's vintage NOS 1971, tires, and one amazing sounding exhaust system. I also have a GTO front bumper, tail lights, repop GTO valance and GTO hood. If any GTO guys read this I still need front turn signals and grilles!

specs, 350 2bbl, th400, PS, AC, 130,000 miles, zero rust. It came from Lubbock Texas, Milner Pontiac(if any Texas members see this and find a Milner dealer ad for my trunk lid let me know!!) This car had not run since 1984! Changed out to HEI, replaced the wires, and it started up and ran on 28 year old gas. I know it wasn't the smartest thing to do, but the gas did smell good. Probably still had lead in it. From what I can see it is still the original top although it needs to be changed now. I want to hold off until I paint if possible.

[da-burb]

by the way, is the RH side a mirror image of the LH? If it is I will leave my pdf alone. If you had to adjust it some I will do a tracing of the RH side and scan it to pdf so it will be correct.

[mrein3]

I'm kinda late to this party. FWIW, I used a hole saw to cut those side vents. You need to figure out where the center is, make a pilot hole, then cut with the hole saw plunging it straight at the dash. I could tell you the size of the hole saw I used but I'm in Paris and the saw is in my shop in Minnesota.
I used a 1/2" drill and took my time as there is a lot of torque cutting that hole with the contour of the metal.
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