Cutting my Truck

I'm about to install a new front bumper from ADD (Honey Badger) and I need to cut the front fenders. I don't want to "F" it up and I'm a little nervous. (It's a clean 22 OR - for now)

What is the best tool to make the cut? Cutting wheel? Recip Saw? Other?

Any advice from experience on what to do / not to do? I know you guys have a lot of experience.

(I know, I know, I am just going to get it scratched up anyway. I need to get over that also but first I need to get the bumper on)

 

osillating multitool

 

Make sure to measure once and cut twice.

 

Ignore @Jakerou ... his truck is nicknamed "swiss cheese".

 

Put masking tape down before you cut to protect the paint and minimize any accidental scratches.

 

Is that really going to do a good job on the painted part of the fender? Looking at some video's I've seen them use that on the inner black fender liner which is thinner but it seems most use a Dremel or larger cutting wheel for the actual painted fender.

 

+1 on the tape, it should reduce cracking on the part you keep. You can also draw your lines on the tape so you have something to cleanly trace for the cut.

One of the larger round blades for an oscillating multi tool is effectively a cutting wheel that doesn't try and get away from you (don't know if you know, but these were invented for cutting casts off of peoples limbs, without cutting the person). I haven't used one on a vehicle, but they are far and away the best tool for cutting something on your house, where you don't want to cut anything else by accident.

A professional fabricator could likely do a better (faster?) job with a grinder and cutoff wheel, but your average Joe would just fuck something up. A dremel will give more control, but there is still the chance is gets away from you.

 

Yeah, i could see how an oscillating multi tool may be better from the aspect of not getting away from you. I guess if it'll cut baseboards and everything else I have used it for there is no reason is should not work on the plastic bumper. I do need to see if I have a roundish tool though, that would be helpful also.

 

I use simple jigsaw with a fine tooth metal blade. Cutoff wheel can put more heat into paint than saw blade. Watch out for what is behind you cuts.
Make sure tape covers area where base of saw will touch. While cutting, keep base pressed to truck so it isn't hammering but also careful base doesn't tear tape and leave scratches as you go.
Deburr edges when done. I like to use a worn out sanding disc on my angle grinder to gently smooth the edges.

 

Also works great for shortening up mud flaps.

 

So this is what the guy at ADD mentioned, a jigsaw. I think I am most comfortable with a Jigsaw, I just did not think there was enough room underneath for the reciprocating blade but since you mentioned it also there must be.

 

ADD Honey Badger requires cutting the metal fender? Really? Pictures show you cut the plastic bumper cover and the plastic fender flare that extends past the bumper line.

 

Maybe. You'll have to look. I was thinking more in general about cutting body panels. I don't know for certain about that specific bumper you have.

 

I feel like a jigsaw is just going to go apeshit on the plastics and push/pull as compared to a cutting disc.

I’ve done it in a 4Runner with a utility blade just making multiple cuts, then sanding smooth up to like 1000+ grit.

 

Ive heard good things about nibblers. Much easier to control

$38 REXBETI Double Headed Sheet Metal Nibbler, Drill Attachment Metal Cutter with Extra Punch and Die, 1 Cutting Hole Accessory and 1 Step Drill Bit, Perfect for Straight Curve and Circle Cutting (Gold)

https://www.amazon.com/dp/B07FFS3CG6/?coliid=I1W6NGP762EG8U&colid=1SGVDF9Q296E9

 

If you're cutting plastic, I would use an oscillating saw with the only blade from Harbor Freight that is decent. I have cut plastic, wood, metal with this thing. The rest of harbor freight blades are junk IMHO

 

No metal, just plastic, but either way I don't want to F it up. I've put so much work into this truck, I am just trying to figure out the best method for best results.

 

^For plastic a body saw is best (small reciprocating saw easier to control than sawzall). I've used a cutoff wheel with passable results - the heat causes "hair" and melted plastic globules to form on the cutting edge, which has to be sanded smooth.

Since lower part of the bumper will be discarded after cutting, you can make practice cuts there until you're satisfied with the tool/technique.

 

Good idea. If the first cut does not work and you need a new tool, you can live with the small corner error for a couple of days.