Thread: Enlarging transfer case hole for CDL instal

Originally Posted by laney

John_D2 I only use genuine Dremel cutting wheels as I have found other types aren't as strong and generally don't fit all that well.

That might have been my issue. I ran out after 10 wheels and I had lots to go so I used the 4” angle grinder with an ultra thin blade

A vibrating, as opposed to circular, cutting tool is best for panels.

Something like this: Ryobi multitool

I stupidly got the cheaper non adjustable head type, not realising that the adjustable one existed!(kicking myself now)

Anyhow, reason I got it was for my aluminium radiator/intercooler frame. Needed to cut a tiny sliver off a few sides, and grinder would have made a mess of the aluminium, with much less control.
How I know this is that version one of my attempt didn't turn out too good with the grinder. Used the hacksaw, but even that needs very precise skill and patience .. and obviously more work.

Got the multi tool, hoping it'd help. Had used one many years ago and liked it but that was a Festool branded one .. so could only hope that the Ryobi would have the same fine control feel.
In a word .. for finely trimming panel work .. brilliant!
The semi circular cutting wheel is the one to use, allows good feel and speed control, for example if you mark your panel with lines to where you want to cut.
I didn't like the straight blade for cutting a test panel, but that tool is more for cutting other things(eg. a nail between two timbers, or a bolt or whatever .. just no good for panel cuts.

Al frame is about 3 or so mm thick, and even tho aluminium is soft, it cut fast, and the finished cut needed barely any finishing. I think they say up to 1.8mm steel is fine in the specs. For thick steel like that tho, a grinder would be better.

The beauty of this tool tho isn't just that it allows you good control up to your marked area, it's also that if you marked wrong, or just plain didn't cut enough panel out, and need to trim just a fine mm again, it's far easier than a grinder.
Also the finished cut is very nicely trimmed, unlike with a grinder which chucks out too much crap.
Also, because the grinder will produce a lot of filings, they'll finish up on the transfer/gearbox, being metal they rust and could cause corrosion on the aluminium gearbox/transfer casing too.

Up until I got this multitool, all my panel cutting was with various snips, but they also bend flat sheet as they cut. Not so much an issue for the OPs situation.

Just saying ... these things are awesome. Only reason I chose Ryobi, is that we're already invested in their battery system, no need for other batteries to keep track of.
So if you're already invested in a particular cordless powertool system(eg. Bosch or Makita, or whatever) seriously one of the most handy tools to have at hand.
(then again I have house renos to consider too).