I'm going to be transferring my FMIC over to a new car and want CLEAN HOLES cut for the fmic piping (CFT hacked the cut on my vert). What the best way to cut the holes?

And if it were as easy as using a 3" circular cutting blade then i would ... unfortunately the areas where the holes need to be cut, are a bit of a PITA. (At the corner where the fender meets the bumper)

 

Hole saw

 

Price <--> Simplicity
The cheaper your option, the more awkward of a job you're looking at. But, in order of cheapest to simplest:

-- Hole saw

-- Dremel with routing bit

-- Dremel, routing bit, and snake extension

-- And of course:

 

Sawzall is your friend

 

I'd like to see someone cut a perfect circle with a sawzall.

 

ditto ... its phesable on a large area .. but not in that scrunched corner. I have a dremel but question its potential of actually drilling through steel/alluminum. Especially since I tried cutting a piece of wood with it .. and i snapped htrough about 20 bits lol.

 

A 3" hole saw is under $15.

 

Can you get an angled drill into that area? I might try that in addition to a 3" hole saw. Good luck!