Depending on hole size, plunge cut using Dremel with proper arbor and
EZ metal cutting disc? Might at least cut through most of what's
needed. Especially if the disc is worn down. (smaller OD) Finish with
shorter hacksaw blade? Be mindful of metal swarf if working above fuse
panel. (sounds like you aren't though).

Is there not enough room for a jigsaw? (blade)

Neil.

On 8/1/17, email99@bellsouth.net <email99@bellsouth.net> wrote:
> I'm getting ready to add another air conditioning vent beside the radio
> on my Vanagon and I wondered what tool would be best for cutting a
> square hole in the metal dashboard.  Has anyone cut this metal and what
> tools did you use?  I don't have the room for a saw because the heater
> and other things are in the way.  Has anyone used a hand metal nibbler,
> like is used for modding computer cases, to cut this gauge metal?  What
> other tools would be appropriate?
>

--
Neil n

Blog: Vanagons, Westfalia, general <http://tubaneil.blogspot.ca>

1988 Westy Images <https://picasaweb.google.com/musomuso/New1988Westy>

1981 Westfalia "Jaco" Images, technical <http://tubaneil.googlepages.com/>

Vanagon-Bus VAG Gas Engine Swap Group <http://tinyurl.com/khalbay>