Cutting a Sunroof?

THANKS GUYS! Strange I was thinking of taping it off and cutting with a dremel. Which ever way I choose I going to get some of those cutting discs i am sure I can find other uses for them aside from sunroofs!lol Youcan never have too many Dremel accessories...

Here is another way to approach your sunroof. Tape off the area you intend to be the hole for the sunroof. Make the tape about a 1/64 of an inch smaller than the finished hole will be.

Next scribe the lines of the perimeter of the sunroof with an exacto blade following the tape. Make the first pass light and just scratch the surface. Make several passes so as to cut a groove the knife will follow. If you try to cut too deep on any one pass you will very likely slip outside the line and scratch the body. You can continue cutting the groove until you cut through. Then you finish the opening with a file or a sanding stick. The Dremell may be faster but you run the risk of slipping and making a mess of the body.  

I would recommend a high speed cutter (i.e. #115 or #196) instead of the cutting discs for this particular application. See this link for available tips:

http://www.dremel.com/HTML/products/accessories/carving.html

I would also recommend using the dremel tool to cut an initial hole much smaller than your intended opening, and then doing the final sizing with a hobby knife or CAREFULLY with a Dremel... it's much easier to start small and then open it up rather than starting large, and then having to fill in with putty or sheet styrene.

Good luck.