C1 Door panel installation

[Don Izzo]

I am ready to install the new door panels on my 1960, and have found that the new units purchased don't have the hole punched in the sheet metal for the window crank. They are supplied this way so they can be used for power windows or manual. As my car has manual windows I am faced with cutting/punching or boring the 1 3/8" hole in the sheet metal. I don't want to damage the metal or end up with a ragged hole so I wonder if anyone can give me suggestions on how they accomplished this. Will a hole saw or punch do the job best or what? Thanks!
Don

[David Bodily]

Re: C1 Door panel installation

One real good way to do this is to use a tool common in the electrical business. it uses a punch and die to form an undistorted hole in electrical panels. I saw a tool much like this for sale in Eastman catalog recently.

[Nicholas L.]

Re: C1 Door panel installation

I used a hole drilling attachment that I bought for my drill. It worked fine after I spent a week getting up the courage to drill into something that just cost me $750.00. I drilled the panel from the back while resting it on a 2X4 so the drill would not deform the sheet metal once it went all the way through. Be carefull when cutting the holes for the arm rest screws.You only need a small slit. Good luck.

[Ed Jennings]

Re: C1 Door panel installation

If you install the panels correctly with the spring pressing the sheet metal out to the crank handle, the hole is completely covered and it doesn't really matter if the hole is exactly right. I did some panels for a 61 a couple of years back and went to great lengths to cut the hole exactly as specified in the aim. I might as well have cut a smaller hole with a pocket knife. I am going to install the panels on a 59 tomorrow and I'm not going to cut more than a 3/4" hole.