Originally Posted by 64airstream
This is a timely post for us. We pick up our AC unit and accessories today and plan to cut the same opening in our 68 Overlander next week. Did you make your cut just aft of the concertina door or just forward of the door?
I plan to cut a 4" diameter hole with a hole saw first to feel around for the wires. Your photo helps me know what to expect.
Roy and Marie
The cut is after the concertina door exactly midway between the rectangular and square vents. That left about 3-4" space to the next ceiling light, which is where I connected to 12V
on Circuit 2.
My tool of choice was an angle grinder with a 1mm precision blade for stainless steel because I have really a lot of hours with this tool and can cut fine work with it. I would not recommend anyone to do this cut without a lot of prior experience. Consider also that the panels are under tension and will pop up slightly when cut through. I used that to my advantage to "see" when the panel was cut and not go any deeper.
The cables will be pretty much pressed up to the underside of the aluminium. Basically expect the worst. I think that I had a lucky day.