rjn
Does any body know of someone in the West Yorkshire area that could cut a 400mm square hole in the roof of a VW t5V Van? So that I can fit a roof light!
rjn
Of course, you're right, but I feel very nervous about chopping a great hole in the roof, don't really know what to expect, does the roof flex and vibrate? does the blade jam a lot? do you get a decent cut edge? is it done from the top or from inside? Or am I over thinking this and just get on and do it?
solarman
just take your time and mark the area accurately,measure 2 or 3 times before you do the job,remember measure twice and cut once..
Probably drill a hole at one corner for jigsaw blade to start from and don't rush,probaly easier from above.
Probably drill a hole at one corner for jigsaw blade to start from and don't rush,probaly easier from above.
David & Ann
Take your time. First, get all the tools you need together. I would use a compass to draw your circle. Make sure the outside of drill size for the blade is within the 400mm you want to cut. File and emery your edges before fitting.
oldish hippy
Forum Member
plus paint the edges with at least two coats when they did my windows on conversion they didn't paint them well if they did they didnt do a good job they need taking out and painting properly but that will have to wait till i can afford to get it done
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groyne
Jigsaws produce a lot of metal filings, don't cut on a windy day, try to contain the filings and clean them up as best you can. Or you'll end up with a rust speckled roof.
David & Ann
Of course OH. Just hope he does not cut the hole when it is pouring down with rain.☺☺☺☺
Firefox
He says it's a 400 square hole
Depending on the roof light fitting instructions, it's generally easier to frame round the hole with say 25x25 timber which is fitted onto the main spars of the roof (H frame with two bars in the H!). Your roof covering can fit under this and insulation be sandwiched in between.
The way I have done it is mark out exactly with pencil and straight edge on the underside of the roof where you want the hole. Then frame it leaving the pencil lines just visible. Then centre punch the corners. Go up on top and find the 4 centre punch bobbles join them up and hopefully you will still have a 400x400 square (measure it again and adjust if necessary). Put masking tape round the outside of the lines to protect the paint from the footplate of the jigsaw. Now drill 4 x 10 or 12mm holes in each corner (on the inside of the lines)(from the top). Insert the metal blade jigsaw in each hole in turn and cut one side (from the top). Yes it will vibrate and catch depending on the quality of your blade but the wood framing below helps stiffen the edges. Wear goggles when cutting metal. Tidy up the edges and corners of the hole and debur with a metal file.
No doubt you can also cut the hole from the inside of the van but I prefer working downwards and also if you frame it on the inside you can get the footplate right on the metal for an accurate cut if you do it from the top. Good luck!
David & Ann
He says it's a 400 square hole
Depending on the roof light fitting instructions, it's generally easier to frame round the hole with say 25x25 timber which is fitted onto the main spars of the roof (H frame with two bars in the H!). Your roof covering can fit under this and insulation be sandwiched in between.
The way I have done it is mark out exactly with pencil and straight edge on the underside of the roof where you want the hole. Then frame it leaving the pencil lines just visible. Then centre punch the corners. Go up on top and find the 4 centre punch bobbles join them up and hopefully you will still have a 400x400 square (measure it again and adjust if necessary). Put masking tape round the outside of the lines to protect the paint from the footplate of the jigsaw. Now drill 4 x 10 or 12mm holes in each corner (on the inside of the lines)(from the top). Insert the metal blade jigsaw in each hole in turn and cut one side (from the top). Yes it will vibrate and catch depending on the quality of your blade but the wood framing below helps stiffen the edges. Wear goggles when cutting metal. Tidy up the edges and corners of the hole and debur with a metal file.
No doubt you can also cut the hole from the inside of the van but I prefer working downwards and also if you frame it on the inside you can get the footplate right on the metal for an accurate cut if you do it from the top. Good luck!
You are right Firefox. I stand corrected. Hope to god he does not cut a round hole. ☺☺☺ Sorry about the error.
Firefox
No probs, it reminded me of a magic trick I have seen called squaring the circle :lol-053:
Squaring the circle - YouTube
It's more a children's party effect... not too difficult to figure out
Squaring the circle - YouTube
It's more a children's party effect... not too difficult to figure out
rjn
Hi All
Gordon Bennett! didn't expect such a response. Thank you every body, very helpful advice! Thanks again! Will try it when it's not raining.
Gordon Bennett! didn't expect such a response. Thank you every body, very helpful advice! Thanks again! Will try it when it's not raining.
oldish hippy
Forum Member
fit a washing machine door in the sides seen it done on old merc on flea bay
rjn
fitted it this afternoon
Fitted the roof light this afternoon, first dry afternoon in weeks! took about 3hrs to do, checking things all the way! I was able to cut through the roof lining board at the same time, which has saved stripping it out and cutting the hole separately. I used 6mm Depron bedded down on carafax mastic to pack out the ridge valleys and then made sure that there was plenty of mastic around the whole area to ensure that it will be water tight. Smoothed the fillet around the roof light frame with a finger dipped in white spirit which helps to smooth the surface. Looks pretty neat, touch wood it'll work OK!
Thanks everybody for your advice and encouragement.
Fitted the roof light this afternoon, first dry afternoon in weeks! took about 3hrs to do, checking things all the way! I was able to cut through the roof lining board at the same time, which has saved stripping it out and cutting the hole separately. I used 6mm Depron bedded down on carafax mastic to pack out the ridge valleys and then made sure that there was plenty of mastic around the whole area to ensure that it will be water tight. Smoothed the fillet around the roof light frame with a finger dipped in white spirit which helps to smooth the surface. Looks pretty neat, touch wood it'll work OK!
Thanks everybody for your advice and encouragement.
Firefox
Well done for having a go and getting it done!
herbenny
Well done for giving it a go glad it worked for you and the sun stayed out long enough for you to get it done........that is the one thing I would love to change about our van and that would be to have a roof light.
Byronic
Conversely as Maximilien Robespierre once said, get it wrong and it's a right pain in the neck.
To David and Ann, at least cutting a 400mm diameter hole when you should have rightly cut a 400mm square hole' wouldn't be half as disastrous as the other way round!!
ellisboy
Nice one Chap! :banana:
Makzine
Well done for having a go, personally I would have used a 4" grinder with a thin disc but thats just me obviously :cool1: