trim holes

[62galxe]

one of the replacement fenders that came with my 57 is off a fairlane and has no trim holes. any suggestions on making square holes.

[JimNolan]

Small file. Beware that if you use a screw type clip you have to trim the excess screw coming out of the nut. There's about 1/8" between that nut and the body to get the front fender to position in place. Jim

[Ford Blue blood]

Also check with machine shop suppliers for "chassis punch".  I have a set that came out of a military salvage store, they make 1/8" to 1/2" square holes and 1/4" to 1" round holes.  You drill a 1/8" hole and insert one have the punch through with the bolt and the cutting head on the othe side, tighten down until the hole is through.  Works on sheet metal to 16 ga.  I have had them for years, do not recall the name of the place, it was in Norfolk, VA.  They make perfect hole and do not distort the metal.

[Meteorman]

mark the centre of the hole, mask out the square you need drill the hole the size so the drill bit will touch the 4 sides, get a pointed dremmel and take out the corners.

[suede57ford]

You could also do all round holes and use universal clips with nuts on most all of the holes.  If you make the square holes too big, they could show if in the wrong place.   Good tip on the fender not having alot of room on the cowl from the earlier post!