So, we have the center hole. No turning back now. Now that I have a 4.5" hole cut in the sheet metal, it gets kinda flimsy. So, I need to stiffen it up with a doubler. Generally, doublers need to be heavier than the base metal. So I opted for .063".
I drew it out using the redneck compass method. I cut it out using a jigsaw, which is time consuming.
This is the doubler in rough out mode. I laid out the hole pattern and did a few other things that I left out that are self explanatory.
I clecoed the plate in place. If you don't know what a cleco is, I'll explain.
|This is how I store my clecos. Just drill a series of holes in a piece of aluminum.|
You can buy used clecos from a place called "The Yard" in Wichita, Ks.
How do they work? Basically, you drill a hole in both parts and using special "cleco Pliers", you depress the cleco and push it through both sides, then release. You're done.
|This a pic of the doubler installed with the light in place, kinda ugly.|
The final product. I still need to round up the chrome pieces to dress it up, but I still have time.