Advice on hole saw please

[Sideshow Bob]

This thread has made me smile because of all the helpful advice on using a hole saw, I used them for many years when I was in instrumentation and building control panels etc and I thought I was the only sad person who thought that he was an expert on hole saws / tank cutters but it seems I’m not on my own

 

[BaileySteve]

The Ledcom lights are a good choice as they give a good spread of light close to the van the headlights don’t cover. In this photo the van is slightly nose down and they are on the dimmed setting.

The higher you can get the van the better.

I went a stage further and installed a set of Hella Rallye 3003’s with led sidelights although this is a lot more work as had to fit light bar bracket, make up looms, wire in relay and fuse etc.

 

[Ingwe]

By way of a brief update, I went to check on the van this morning as it’s kept in secure storage about 5 miles away. Had a look at the place where the running lights will go and also photographed the instructions from Ledcom.

I must have seen a video about fitting these lights where they talked about using a 76mm hole saw to make the hole because the instructions don’t refer to a hole saw; they just show the diameter of the lights and the how they cut the space for the lights. This was why, originally, I’d contemplated using an oscillating multitool to make the suggested cuts.

The instructions make clear that you may have to remove the skirt to access the hole and of course, it had to be the case for me! I looked underneath and it seems that there is a number of screws into the wheel arch itself holding the plastic cover in place but one nut and bolt also. If anyone has removed this cover, I would appreciate their feedback as to how simple this removal is. I also put a photo of the covered hole as it does look to me that it would need cutting rather than unclipping as seems to be the case in later Boxer models.

Looking at the photo, it looks like the whole inset may come out (see gap in the top left of photo) which would certainly make cutting the hole for the lamp a whole (no pun) lot easier.

Comments, suggestions and advice always appreciated.