Suggestions for cutting the wheel well. - The 1947 - Present Chevrolet & GMC Truck Message Board Network

gchemist · 09-01-2007, 09:33 AM

I need suggestions on how to cut a 4.5" hole in the wheel wells.

I need the holes to run 4" ducts for a ram air box. I don't have a plasma cutter or anything fancy. I do have a lot of common garage tools. The ducts will have the intakes run from the bumper. I'm thinking of using a 4" straight duct then use flexible duct to make the connections. The first connection will from the bumber to the straight duct. The second from the top of stack to the air box.

The final look will like this setup.

ont_guy_38 · 09-01-2007, 10:10 AM

Use a jigsaw with a metal blade.thats about the easiest way with average tools.I have put sunroofs in using that method

Srubydo1986 · 09-01-2007, 10:49 AM

i dont think it a good idea the consept is great but the factory 4 inch hole the the front suport are what really were its bests.

Here y or at least i think y by puttinh in the well well u will suck up more road dubre/ dirt and if your diving and it rain ur going to suck up water. just a thought

gchemist · 09-01-2007, 11:07 AM

Which four inch hole?

Restrorob · 09-01-2007, 05:39 PM

There should be two stamped knock-outs as below, I even have them on my 74 and plan on running mine to them.

gchemist · 09-01-2007, 07:05 PM

The core support on my truck is a 91. The holes are taken up by the side by side headlights. The bezels cover up everthing else. I might find something createive too.

Restrorob · 09-01-2007, 08:16 PM

Sorry, As many post I've seen about your truck I couldn't remember what year it is....

gchemist · 09-01-2007, 08:36 PM

A board user has suggested a NASCAR option. Turn the air box 180 and cut holes in the fire wall. Use the cowl for cold air intake. Sounds interesting but the brake booster poses a problem. I'll have to mount the air box and checkout the option.

Ram Air Box makes them too! The NASCAR style box.
http://www.ramairbox.com/models.html
This web page has pictures of several installations.
http://www.ramairbox.com/install.html
The setup would not cover up the RPM Aig Gap intake like the dual snorkel option.

Look at the 95 Chevy truck and the 99 Dakota. The configuration fits what I'm trying to do.

**N2TRUX** · 09-01-2007, 11:06 PM

This would be my choice-

slugish · 09-01-2007, 11:08 PM

Ive got the ram air box on mine . Ihave the stock 84 radiater support frame , so Ive got mine into the holes already there. Do you or anybody know where you can get smooth 4 in. aluminum tubing . Ihave the dryer hose style & dont like the way it looks. you also can buy the smooth tubing from air inlet systems , but the only way it comes is black (aluminum just looks a lot beytter) & you cant paint it either . You would still have to use flexible couplings, if the smooth was available.
These systems are really eye catchers at shows , cruise ins etc. most all the hot cars & trucks have the old school open elements as you well know.

gchemist · 09-01-2007, 11:16 PM

Try a commercial A/C place. Or visit HomeDepot or Lowes. The smooth Al looks at lot better.

09-01-2007, 09:33 AM	#1
gchemist BAD BOW-Silverado XST Join Date: May 2000 Location: Senior Member from Austin, TX Posts: 6,431	Suggestions for cutting the wheel well. I need suggestions on how to cut a 4.5" hole in the wheel wells. I need the holes to run 4" ducts for a ram air box. I don't have a plasma cutter or anything fancy. I do have a lot of common garage tools. The ducts will have the intakes run from the bumper. I'm thinking of using a 4" straight duct then use flexible duct to make the connections. The first connection will from the bumber to the straight duct. The second from the top of stack to the air box. The final look will like this setup. __________________ Gerardo a.k.a. Mad Chemist Silverado XST videos

09-01-2007, 10:10 AM	#2
ont_guy_38 Registered User Join Date: Jul 2007 Location: Ontario Canada Posts: 1,006	Re: Suggestions for cutting the wheel well. Use a jigsaw with a metal blade.thats about the easiest way with average tools.I have put sunroofs in using that method

09-01-2007, 10:49 AM	#3
Srubydo1986 The Crazy Machanic Join Date: Jan 2007 Location: Nokesville Va Posts: 1,437	Re: Suggestions for cutting the wheel well. i dont think it a good idea the consept is great but the factory 4 inch hole the the front suport are what really were its bests. Here y or at least i think y by puttinh in the well well u will suck up more road dubre/ dirt and if your diving and it rain ur going to suck up water. just a thought __________________ 1986 Sliverado longbed 400 small block mean as hell, 700r4 trans (5 speed coming one day) 1970 chevelle 2dr sedan Latest update June 24 2007. *1957 4 door stationwagon - pink all original needing a good restore (body great, floors bad) newest additions 1965 shortbed fleet great granddads. Been told im nuts to bring it back from the dead (still going to happen) plans-all stock with a turbo 292 inline 3 speed column shift. and thats it big block 427 and 5 speed trans and ford 9 inch theyhave no home yet thinking what to put them in and a 79 c60 trash truck um no idea i have one

09-01-2007, 11:07 AM	#4
gchemist BAD BOW-Silverado XST Join Date: May 2000 Location: Senior Member from Austin, TX Posts: 6,431	Re: Suggestions for cutting the wheel well. Which four inch hole?

09-01-2007, 05:39 PM	#5
Restrorob The One And Only !!! Join Date: Jan 2007 Location: Hole in the woods Florida Posts: 4,567	Re: Suggestions for cutting the wheel well. There should be two stamped knock-outs as below, I even have them on my 74 and plan on running mine to them. __________________ 93 Jeep XJ 88 Buick La Sabra Toys; 88 TA-GTA in the works.... 97 GMC Ext. Cab 502 Crate 5 Spd......Sucks Gas But Haulz Azz ! The primary function of an Engineer is to make it difficult for the Fabricator and impossible for the Mechanic. *"Why go out preserved when you can go out beat up, worn out, sliding in sideways screaming, Holy Sh!t What A Ride" !!!*

09-01-2007, 07:05 PM	#6
gchemist BAD BOW-Silverado XST Join Date: May 2000 Location: Senior Member from Austin, TX Posts: 6,431	Re: Suggestions for cutting the wheel well. The core support on my truck is a 91. The holes are taken up by the side by side headlights. The bezels cover up everthing else. I might find something createive too. __________________ Gerardo a.k.a. Mad Chemist Silverado XST videos

09-01-2007, 08:16 PM	#7
Restrorob The One And Only !!! Join Date: Jan 2007 Location: Hole in the woods Florida Posts: 4,567	Re: Suggestions for cutting the wheel well. Sorry, As many post I've seen about your truck I couldn't remember what year it is.... __________________ 93 Jeep XJ 88 Buick La Sabra Toys; 88 TA-GTA in the works.... 97 GMC Ext. Cab 502 Crate 5 Spd......Sucks Gas But Haulz Azz ! The primary function of an Engineer is to make it difficult for the Fabricator and impossible for the Mechanic. *"Why go out preserved when you can go out beat up, worn out, sliding in sideways screaming, Holy Sh!t What A Ride" !!!*

09-01-2007, 08:36 PM	#8
gchemist BAD BOW-Silverado XST Join Date: May 2000 Location: Senior Member from Austin, TX Posts: 6,431	Re: Suggestions for cutting the wheel well. A board user has suggested a NASCAR option. Turn the air box 180 and cut holes in the fire wall. Use the cowl for cold air intake. Sounds interesting but the brake booster poses a problem. I'll have to mount the air box and checkout the option. Ram Air Box makes them too! The NASCAR style box. http://www.ramairbox.com/models.html This web page has pictures of several installations. http://www.ramairbox.com/install.html The setup would not cover up the RPM Aig Gap intake like the dual snorkel option. Look at the 95 Chevy truck and the 99 Dakota. The configuration fits what I'm trying to do. __________________ Gerardo a.k.a. Mad Chemist Silverado XST videos Last edited by gchemist; 09-01-2007 at 09:40 PM.

09-01-2007, 11:06 PM	#9
N2TRUX Happy to be here Join Date: Mar 2000 Location: Cypress, TX Posts: 39,021	Re: Suggestions for cutting the wheel well. This would be my choice- __________________ Follow me on Facebook and Instagram @N2trux.com Articles- "Jake" the 84 to 74 crewcab "Elwood" the77_Remix 85 GMC Sierra "Scarlett" "Refining Sierra"

09-01-2007, 11:08 PM	#10
slugish Slugish Join Date: Jan 2005 Location: Earlysville, Va. Posts: 1,024	Re: Suggestions for cutting the wheel well. Ive got the ram air box on mine . Ihave the stock 84 radiater support frame , so Ive got mine into the holes already there. Do you or anybody know where you can get smooth 4 in. aluminum tubing . Ihave the dryer hose style & dont like the way it looks. you also can buy the smooth tubing from air inlet systems , but the only way it comes is black (aluminum just looks a lot beytter) & you cant paint it either . You would still have to use flexible couplings, if the smooth was available. These systems are really eye catchers at shows , cruise ins etc. most all the hot cars & trucks have the old school open elements as you well know.

09-01-2007, 11:16 PM	#11
gchemist BAD BOW-Silverado XST Join Date: May 2000 Location: Senior Member from Austin, TX Posts: 6,431	Re: Suggestions for cutting the wheel well. Try a commercial A/C place. Or visit HomeDepot or Lowes. The smooth Al looks at lot better. __________________ Gerardo a.k.a. Mad Chemist Silverado XST videos



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