Cutting a neat hole in headlining (or any soft material).
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Thread: Cutting a neat hole in headlining (or any soft material).

  1. #1
    1000+ Posts Fordman's Avatar
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    May 2004
    Perth/West Australia

    Default Cutting a neat hole in headlining (or any soft material).

    A new trick learnt for an old dog.
    Installing a cargo barrier in the Territory today, required brackets installed above headlining, and cutting a 19mm dia hole where the attaching screw will be fitted (2 locations). Being of a fabric/foam/fibreboard construction, I guess the chance of stuffing up is fairly high, so the instructions gave a couple of good tips on getting it done safely.
    Firstly, the trick to marking the location was a short 10mm thread with a pointed end (supplied), which temporarily screws into the bracket, headlining positioned, then pressing around the area finds the point, and a bit of pressure confirms the position of the required hole. I then put some masking tape over that position to mark the location with a felt pen. After removing temporary pin point, I then used a thin centre punch through the mark which again located the "nut" and opened up to approx 6mm dia.
    The main tip was to modify a 19mm holesaw by grinding off the teeth and grinding a chamfer down to a knife edge. Replace the centre drill with a piece of 6.3mm steel rod (I am guilty of destroying an old screwdriver to get that bit) with a small chamfer, to guide the saw without enlarging the guide hole.
    Heart in my mouth as I drilled into a new car's headlining, but it worked a treat.

    Main picture shows the modified holesaw, the centre pin marking screw, and the two neat offcuts after a few seconds drilling. One pic with masking tape, and one the finished hole.


    Anyway, a pretty neat trick which may come in handy for future jobs.

    Cutting a neat hole in headlining (or any soft material).-img_20180923_180534408_small.jpgCutting a neat hole in headlining (or any soft material).-img_20180923_180402368_small.jpgCutting a neat hole in headlining (or any soft material).-img_20180923_180747647_small.jpg

    Last edited by Fordman; 24th September 2018 at 10:32 PM. Reason: As in italics
    Kenfuego, Roland, JohnW and 3 others like this.
    2004 Scenic I 2.0 auto (Hers)
    2016 Ford Territory (His)
    2004 WRX (Sunday car)

  2. #2
    Too many posts! JohnW's Avatar
    Join Date
    Jul 2001
    Perth, WA, Australia


    Very neat. Thanks for that!


    Renault 4CV 1951
    Renault R8 1965
    Renault Scenic 2005 (wife's)
    Renault Scenic 2007 (mine)
    Renault Scenic 2006 (daughter's)
    CitroŽn CX Pallas 1980

    National Co-ordinator, Renault 4CV Register of Australia

  3. #3
    1000+ Posts CEyssens's Avatar
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    Jan 2016
    Berwick VIC AUS


    Thanks for sharing, cheers.

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