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  #11  
Old 09-30-2014, 10:22 PM
Dave Bernard's Avatar
Dave Bernard Dave Bernard is offline
 
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Why not just cut a square? Proseal will seal it all up just fine.
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  #12  
Old 10-01-2014, 08:23 AM
rv7charlie rv7charlie is offline
 
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Quote:
Originally Posted by Dave Bernard View Post
Why not just cut a square? Proseal will seal it all up just fine.
Good question. :-)

Whatever shape the hole, another option is a 'trim router' or 'cutout tool'
http://www.harborfreight.com/14-in-t...ter-61626.html
http://www.harborfreight.com/electri...ool-42831.html
and a plunge type spiral cut bit. You can get high speed steel and carbide bits at any big box store. If it will cut wood, it will cut aluminum. Same principle as the circle cutters shown in earlier posts, but the tool has other uses, too.

A plywood or MDF pattern could be clamped to the back baffle, so that the bit follows the inside of the hole pattern.

Charlie
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  #13  
Old 10-01-2014, 09:58 AM
Mike H Mike H is offline
 
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Quote:
Originally Posted by Dave Bernard View Post
Why not just cut a square? Proseal will seal it all up just fine.
If you make an access panel or repair patch square you will need to ensure you have sufficient corner radius to prevent stress and resulting cracks. An easier way to take skin stress into consideration is to make the access panel circular, this is most likely the reason why round access panels are called out in this application
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