QUOTE(Dave_Darling @ Oct 14 2023, 01:16 AM)
Don't use a template, it's too easy to get it just a little bit off.... And then you can't use the weld-nuts on the door!
The right way: Take the door card off. Locate the two weld-nuts. Center punch through them from inside the door. Go to the outside of the door and punch the other way. Carefully drill undersize, then slowly go up in drill sizes until just below the size of the screws. (M6, I believe.) Then go very very carefully and just open up the sheet-metal of the door skin to the final diameter.
AFAIK, only 914 door mirrors have the correct bolt spacing to fit.
--DD
I have a tool tip for this as well.
Unless you are stupid lucky the hole you start to drill is never really centered and you have to "walk" the hole with increasingly larger bits.
With practice you will get better at this.
Here's a way that will give nearly perfectly centered holes for a beginner with a couple of extra tools.
Get a Dremel and a real carbide bit for it. These bits NEVER come in the assortments and have to be purchased separately. They are some of the more expensive Dremel bits. I expect $10 per bit.
With the real carbide bits you can write in cursive in sheet metal!
They have so much control they can correct the hole you made to the point it looks factory.
I'd follow Dave's instructions up to the point I drilled the first undersized hole and finish them with the Dremel. I suggest a "practice" hole or two in a bit of sheet metal BEFORE you employ this method on a door skin. Old license plates would be a good material for this practice.
For softer material you can use the drywall bits in the same fashion. Aluminum sheet and softer respond well with the drywall bits.
I'm really good with the old school "walk the drill" process and I will never do it that way again as long as I have my Dremel...