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Electrical & Computer SystemsDetails discussions regarding electrical components, wiring, all lighting, wire harnesses and HID conversion for your vehicle.
This is a discussion thread titled "Cool Turn Signal Mod - CHEAP!", within the Electrical & Computer Systems forum, part of the Technical & Vehicle Assistance Forums category.
I have a nibbling tools and would NOT recommend using one for a couple of reasons:
1) Most nibbling tools I have used are for very thin metal. If you try to use them on thicker sheet metals, they bend the metal rather than cutting it making for a sloppy cut.
2) They can leave a "trail" (scratches) on the paint unless you are VERY carefull, and you won't be able to get the tool on the inside of the fender (which is where you should be cutting from) to get the proper finish.
I am not sure if there are better quality "nibblers" out there or not.
I wouldn't use aviator or tin snips either for essentially the same reasons, but mainly because the metal tends to get bent when cutting.
As I mentioned, I drilled several holes inside the lines of the oval I had drawn to cut out. I then put a couple of layers of masking tape all around the area (about 6" wide) where the hole was going to be to prevent scratches. I used a Dremel tool with a carbide bit to size the hole a little at a time after drilling pilot holes. I also used the router guied attachment installed on the dremel to give me more control. It worked well, just requires a steady hand (coffee not recommended before this task) and a lot of patience.
The lights I installed don't have a huge lip, so there is really not much room for error. That's why I was so concerned about scratches, etc.
I've used both manual and air-powered nibblers before - they're great for cutting out big rust holes for welding new patches onto, but definitely not for painted metal!
The drill/dremel approach is best for this procedure - as is the masking tape!
My cheap-*** lights had plenty of room for a sloppy hole - just make sure to seal up the exposed metal edges before installing.
Great info guys---One more thought then---What about using a Unibit (http://www.crawfordtool.com/unibit.html) for drilling the round area's out first then using a dremel for what is left? Ken the carbide bit, is it like a drill bit or like a little grinding wheel? My thought was to make a template out of A/C sheetmetal first to get the right fit then tranfer that to a piece of sheet magnet that would stick to the truck, tape that in place and follow the outline. In thought it sounds good but who know till it gets started.
I don't know anything about the Unibit, I have never used one. It sounds like you have a pretty good plan in place though. I did essentially the same thing only instead of using sheet metal, I made my template out of thick, clear plastic. I drew the outline of the hole that I wanted on my truck using the template.
I don't have a dremel (but might be able to borrow one) but do have a roto zip. Do you think that would work instead and at what speed did you have it set at to cut the hole. Did you go clockwise or counterclockwise?
I have seen the Rotozip, but never used one so can't really advise on it's use. The Dremel only cuts in one direction (clockwise I think), and I had it set at about 3/4 speed (not sure on the RPMs. probably about 2500).
Stopped by the dealer again to try and find the bulb socket which they do have for $24.00 each. So by the time I buy the 2 markers and the 2 sockets it will cost about $70.00. So Ken the $50.00 you spent on your marker kit was alot better then you thought. He did show me the ones for the Bettle which are LED markers @$56.00 each which has about the same hole but mount a little different. Decision-decision
Someone had asked earlier if the lamps that I used came with a "gasket". They did not. I was a little concerned about water leaking in around the light because of the way the light fits in. I don't think VW makes a gasket for these lights, so here is what I did:
I went to Home Depot and bought 2 large O-Rings (I have the size if anyone needs them). They slipped on right over the lights and make a pretty good seal. They look pretty stock too. I love when there are simple, cheap (about $1) fixes for stuff like this!
If anyone need the part numbers or size let me know and I will post. I may post some new pics too.
Someone had asked earlier if the lamps that I used came with a "gasket".
I believe that would have been me. After cutting them in I primed and painted the holes and because of the way they come out I take then out and wax around the holes to help protect from rust. I thought you needed a gasket to keep the water out but not worried since it just rolls down the inside of the fender and to the ground. Great mod and is something different from everybody else's truck and was really easy to do.
