old school van '84. Thick metal. I have the hole to accomodate a 6.5" to start - going up to fit a 9".

What tool would be best?

What if I had to start a hole from scratch? drill a pilot hole then start from there?

 

Use ear protection when cutting metal, you will thank yourself.
How about a nibbler or high speed die-grinder with a tungsten carbide bit??

 

Haven't seen a nibbler in years, nice mess they make though. A pissed off Alligator might do the job. I like to use my airsaw as well, failing that a damn good set of left handed cut tin snips.

 

thanks.

snips out as I'm left handed and to this day can't use a pair of scissors - left handed or not.

air saw - rentalex?

 

Dynamite !!!

Electric nibbler. Yes messy. Yes fun to use. Yes I enjoyed cutting up many other people's cars with it

 

Plasma cutter, if you have access to one makes a beautiful hole.......

 

I've used tin snips in the past... but I also made a horrible mess...

Last time I had to cut a hole in my car I used my dremel with a grinding wheel... it did a pretty nice job... probably not as fast as a few other methods mentioned though....