I got the abs panel kit for my 51 from classic haulers. The panels around the back glass fit the 49/50 with the smaller glass. They said it would need to be trimed to fit. I was hoping someone has done this and might offer a few tips on the best way to get it done RIGHT. I will also have to cut hole for gas tube.

 

I'm not sure of the best way but I think that for long straight cuts you could probably get a nice smooth cut by scoring it and breaking it. For curved areas I'd consider a jig saw or a pnuematic body saw would do the trick.
You can get one cheap at Harbor Frreight


If you do make a horrible mistake the stuff can be glued back together. Since its ABS you can get the cans of glue at your local hardware store in the plumbing secction. I think you could use some acetone or MEK to smooth any rough areas as well.

If you get a chance, take lots of pics, I'd love to see how it all fits up. Since I have a 49 I won't have to worry about making the cuts in my truck

Bobby

 

The only thing I would add to bobbytnm's suggestion is to cut away from your scribed line and take it down to the line with a file and don't cut to fast with the air saw as the abs melts under the friction, good luck and go slow.

 

I used a set of sheet metal shears and a body saw like Bobby shows plus a heat gun ( watch the heat gun it works fast ).

Chuck

 

Been wondering about this myself, I have a roof console and have to fit the headliner up against it both sides. Good suggestions, thanks

 

I did mine from abs sheets from a plastics wholesaler and cut it with a sheet metal shears. I tried a saw like the one in a prior post and it's hard to control (the abs vibrates like crazy) and the saw leaves scratches. Leave it alittle big and file for a clean look. If I could figure out how to post pics, I'd show you the final product. Kind of frustrating. Hope that helps. Go slow, measure twice, cut once!

 

Good tip on the metal sheers. Sounds like it would be a whole lot easier and cleaner than the power saws

Bobby

 

I like the score with a utility knife and snap method. You don't have to cut deeply, just a light single cut with the point of a new blade like you are drawing a line with the knife and bend away towards the unscored side. It will snap off clean as a whistle even around curves. Avoid using anything that leaves a jagged edge, each nick or scratch can start a crack. Sand smooth with 320 sandpaper wrapped around a dowel or other hard round object near the diameter of any inside curves. If you use any type saw, scrape (not cut) the fuzz off the edge with a knife blade held perpendicular to the surface and at a 45* to the edge or with sandpaper block held 45* to the edge. As stated you can use plastic pipe glue (be sure it is specifically for ABS, not for PVC) but glue from the back (easy with the glue, you don't want to soften the plastic all the way thru and reinforce the glue seam with a patch of scrap ABS on the back if it won't make it too thick. Give the glue an hour or more to dry completely before handling.